Lincoln Electric RANGER 225 GXT Operator'S Manual Download Page 34

Page: 34 / 37

F-3

DIAGRAMS

F-3

WELDMARK 225

OF SHAFT

9.29

21.21

9.31

2.75

17.00

26.59

19.11

30.28

9.09

UNDERCARRIAGE MOUNTING HOLES

42.25

CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK.

11.31

21.95

FOR OIL FILTER REMOVAL

30.00

8.80

30.00

42.00

M17215-2

1-30-98E

Summary of Contents for RANGER 225 GXT

Page 1: ... 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 R Manufactured by Lincoln Electric Company Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com Copyright 2005 Lincoln Global Inc This manual covers equipment which is no longer i...

Page 2: ...R WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is availa...

Page 3: ...ical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3...

Page 4: ...event 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 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Weldin...

Page 5: ...s et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloign...

Page 6: ... followed to avoid minor personal injury or damage to this equipment CAUTION 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 e...

Page 7: ...Starting the Engine B 3 Safety Precautions B 3 Stopping the Engine B 3 Break In Period B 3 Welding Process B 4 Duty Cycle B 4 Stick Constant Current Welding B 4 TIG Constant Current Welding B 4 DC Wire Feed Welding Processes CV B 4 Summary of Welding Processes B 5 _________________________________________________________________________________________ Accessories Section C General Options Accesso...

Page 8: ...nstant Current 225A 25V 100 DC Constant Current 210A 25V 100 DC Constant Voltage 200A 20V 100 Auxiliary Power 8 000 Watts 60 Hz AC 70 Amps 115V 35 Amps 230V PHYSICAL DIMENSIONS Make Model Kohler CH20S Description 2 cylinder 4 Cycle Air Cooled Gasoline Engine Aluminum Alloy with Cast Iron Liners Electrical Ignition Speed RPM High Idle 3700 Full Load 3500 Low Idle 2200 Displacement cu in cu cm 38 62...

Page 9: ...0 100 150 200 250 0 10 20 30 40 50 60 70 80 DC STICK TIG CC OUTPUT OUTPUT AMPS OUTPUT VOLTS DC RMS A 210 OUTPUT RANGE B 50 OUTPUT RANGE A B 0 50 100 150 200 250 300 350 0 10 20 30 40 50 60 70 80 CV OUTPUT RANGE 0 50 100 150 200 250 300 OUTPUT AMPS 350 0 5 10 15 20 25 30 35 40 DC WIRE FEED CV OUTPUT OUTPUT VOLTS DC RMS SPECIFICATIONS ...

Page 10: ...s 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 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 K894 1 spark arrester ...

Page 11: ...cted cable securely to the negative battery terminal before attempt ing 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 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...

Page 12: ...allow muffler to cool before touching muffler The Weldmark 225 is shipped with the exhaust com ing out on the left side The exhaust can be changed to the opposite side by removing the two screws that hold the exhaust port cover in place and installing the cover on the opposite side Operating the Weldmark 225 without the cover in place will result in a higher noise level and no increase in machine ...

Page 13: ...her 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 100 for both welding and auxiliary power AUXILIARY POWER Start the engine and set the IDLER control switch to the High Idle mode Voltage is now correct at the receptacles for auxiliary power This must be done before a trip...

Page 14: ...GFCI duplex Receptacles No Welding NEMA 5 20P Plug required for 20Amp Draw 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 230 volt motors The motor may be run at full load when plugged into only one side of the dup...

Page 15: ...ESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS Inductive Single phase induction motors These devices require large drills well pumps grinders small current inrush for starting refrigerators weed and hedge Some synchronous motors may trimmers be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures Capacitive Inductive Computers high re...

Page 16: ...educe output voltage below the allowable 10 of rated voltage which may damage appliances or other motor driven equipment 3 Install a 50 amp 115 230V plug NEMA type 14 50 to the Double Pole Circuit Breaker using No 8 4 conductor cable of the desired length The 50 amp 115 230V plug is available in the optional plug kit 4 Plug this cable into the 50 amp 115 230V receptacle on the Weldmark 225 case fr...

Page 17: ...EUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE No 8 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS 230 VOLT GROUNDED CONDUCTOR 35AMP 230 VOLT DOUBLE POLE CIRCUIT BREAKER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION 50 AMP 115 230 VOLT PLUG NEMA TYPE ...

Page 18: ...or If Started Under No Load Lights Eighty 100 Watt Incandescent Bulbs Can be Used for Standby Power OTHER FEATURES Bottom Mounted 9 Gallon Fuel Tank with a Convenient Top Fill and Fuel Gauge Polarity Switch for Selecting DC DC or AC Welding Output K930 1 TIG Module Available Remote Control Receptacle Kit Available Electronic Engine Idler Engine Automatically Goes to Low Idle in 10 to 14 Seconds af...

Page 19: ...is being drawn the engine will return to low idle after approximately 10 to 14 seconds 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 ...

Page 20: ... 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 WELD MARK 225 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 ...

Page 21: ...and electrodes are recommended The K930 TIG Module should be used with the Weldmark 225 on high idle to maintain satisfactory operation It can be used in the AUTO position but the delay going to flow idle after welding is ceased will be increased if the AFTERFLOW CONTROL is set above 10 seconds WIRE FEED WELDING PROCESSES CONSTANT VOLTAGE The only Innershield electrode recommended for use with the...

Page 22: ...high idle TIG K7930 1 K938 1 Yes HIGH Cold Press Amptrol contactor K936 K892 1 closes welding WITH AMPTROL starts immediately WIRE FEED LN 25 WITH No AUTO Cold Press gun trigger LN 25 INTERNAL CONTACTOR contactor closes Welding starts immediately and engine goes to high idle NOTE Output Control must be set above 3 WIRE FEED LN 7 WITH Yes HIGH Cold Press gun trigger K240 CONTACTOR KIT contactor clo...

Page 23: ...es with GFCI recep tacles use K802 R 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 K892 1 Remote Control Receptacle Kit Includes a 6 pin MS type Amphenol receptacle and a local remote toggle switch that mounts in the case front...

Page 24: ...le see Optional Equipment Optional K939 1 Docking Kit K963 Hand Amptrol K870 Foot Amptrol K892 1 Remote Control Receptacle Kit K915 1 Adapter Cable 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 solenoid K892 1 Remote control Receptacle Kit and K444 1 Remote voltage Control Kit are req...

Page 25: ...or 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 oil and oil filter are not changed according to the manufacturer s recommendation ENGINE OIL CHANGE Drain the oil while the engine is warm t...

Page 26: ...se 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 Air Cleaner With normal operating conditions the maintenance...

Page 27: ...ositive 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 WELDMARK 225 WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent...

Page 28: ...ker for this receptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI recep tacle This will assure normal GFCI operation Plug a night light with an ON OFF switch or other product such as a lamp into the GFCI receptacle and turn the product ON Push the Test button located on the GFCI recepta cle The night light or other product should go OFF Push the Reset button ...

Page 29: ...abeled 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 Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Authorized...

Page 30: ... 1 Open in miscellaneous leads 2 Open lead in flashing or field circuit 3 Faulty rotor 4 Faulty Potentiometer R1 5 Faulty stator Field winding 6 Faulty Field rectifier D2 7 Faulty P C Board 1 Idler switch on High Idle 2 Insufficient voltage present between terminals 213 and 5E Voltage should be 12V DC 3 External load on welder or auxiliary power 4 Faulty wiring in solenoid circuit 5 Faulty idler s...

Page 31: ...start No auxiliary power 1 No voltage signal from the current sensor 2 Auxiliary power load less than 100 to 150 watts 3 Faulty P C Board 1 Battery will not hold a charge Faulty Battery 2 No or insufficient charging current 3 Loose battery cable connection s 1 Out of fuel 2 Low oil level 1 Fuel filter clogged 2 Air filter clogged 1 Spark plugs do not have specified gap 2 Spark plugs are fouled 1 G...

Page 32: ...Y 4 1 3 2 4 211 IGNITION MODULE 221 B 5H M20049 215 ELECTRICAL SYMBOLS PER E1537 STATOR REACTOR S1 WORK ELECTRODE CHOKE D1 S2 D2 ROTOR C1 PCB1 SLIP RING NEAREST LAMINATION W1 W2 C1 S1 E R1 R2 R4 R5 R6 C1 S2 L1 R3 STATOR REACTOR 2 10 8 1 7 12 6 6 5 3 9 9 7 200A 200 201A 201 219 200B 3 ENGINE CROSS SUPPORT GROUND SCREW GND E GND E GND G 200B 219 201A 224 215 76 5E 75 77 J1 8 10 5D 7 254 B R1 OUTPUT ...

Page 33: ...e Connect it directly to the work piece independent of the welding work cable For convenience this extended 21 lead should be taped to the welding work lead N G Tape up bolted connection where lead 21 is extended N H Idler switch on power source must be in high idle position N J If an optional remote output control is used connect it to this terminal strip or 6 pin Amphenol receptacle NOTE Termina...

Page 34: ... OF SHAFT 9 29 21 21 9 31 2 75 17 00 26 59 19 11 30 28 9 09 9 09 UNDERCARRIAGE MOUNTING HOLES 42 25 CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK 11 31 21 95 FOR OIL FILTER REMOVAL 30 00 8 80 30 00 42 00 C M17215 2 1 30 98E ...

Page 35: ...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 da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 36: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 37: ... Manufactured by Lincoln Electric Company Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com ...

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