Lincoln Electric RANGER 250 GXT (AU) Operator'S Manual Download Page 1

Page: 1 / 36

RANGER 250 GXT

OPERATOR’S MANUAL

For Machines with Code Number:

11400, 11420, 11493, 11667, 11668, 11736, 11737,

11792, 11973, 11799, 11800

IM921-D

February, 2011

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  thoughtful  operation  on
your  part.

DO NOT INSTALL,

OPERATE  OR  REPAIR  THIS
EQUIPMENT  WITHOUT  READ-
ING  THIS  MANUAL  AND  THE
SAFETY  PRECAUTIONS  CON-
TAINED  THROUGHOUT

. And,

most importantly, think before
you act and be careful.

• 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

• World's Leader in Welding and Cutting Products •

Summary of Contents for RANGER 250 GXT (AU)

Page 1: ...increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful 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 l...

Page 2: ...AKER 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 ava...

Page 3: ...or cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produce fu...

Page 4: ...s to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not welding make certain no part of the electrode ...

Page 5: ...riés 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 Elo...

Page 6: ...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 linc...

Page 7: ...t in Shutdown Instructions B 3 Starting the Engine B 3 Safety Precautions B 3 Stopping the Engine B 3 Break In Period B 3 Welding Process B 4 Stick Constant Current Welding B 4 TIG Constant Current Welding B 4 Wire Feed Welding Processes Constant Voltage B 4 Arc Gouging B 4 Summary of Welding Processes B 5 ________________________________________________________________________________ Accessories...

Page 8: ...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 RECEPTACLES 2 120VAC Duplex 5 20R 1 120 240VAC Dual Voltage Full KVA 14 50R bATTERY CHARGING CIRCUIT bREAKER 20AMP for Engine Battery Charging Circuit AUXILIARY POWER CIRCUIT bREAKER Two 20AMP for Two Duplex Receptacle 1 50AMP for Dual V...

Page 9: ...f 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 K1898 1 spark arrester must be installed and pr...

Page 10: ... 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 requirements for use on public highways A 3 INSTALLATION RANGER 250 GXT A 3 PRE OPERATION SERVICE READ the engine operating and maintenanc...

Page 11: ...ed when lifting the machine ADDITIONAL SAFETY PRECAUTION HIGH ALTITUDE OPERATION At higher altitudes Welder output de rating may be necessary For maximum rating de rate the welder output 3 5 for every 1000 ft 305m above 3000 ft 914m If operation will consistently be at altitudes above 5 000 ft 1525m a carburetor jet designed for high altitudes should be installed This will result in better fuel ec...

Page 12: ...ng the idle mode to HIGH Note LN 15 Control Cable model will not work with the Ranger 250 GXT Position the RANGE switch to the WIRE FEED CV position 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 When welding with MIG wire instead of self shielded core wire w...

Page 13: ...TION 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 250 GXT is 100 AUXILIARY POWER The Ranger 250 GXT can provide up to 10 000 watts of 120 240 volts AC single p...

Page 14: ...WITHOUT ADDI TIONAL 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 resolution TV...

Page 15: ...m 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 3 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 ...

Page 16: ...nection of Ranger 250 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 Figure 1 CONNECTION OF Ranger 250 GXT TO PREMISES WIRING WARNING ...

Page 17: ...o 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 b 1 OPERATION RANGER 250 GXT 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...

Page 18: ...r 5 69 Liters Hour 1 41 Gallons Hour 5 33 Liters Hour 1 48 Gallons Hour 5 62 Liters Hour Low Idle No Load 2400 RPM High Idle No Load 3700 RPM AC CC Weld Output 250 Amps 25 Volts DC CC Weld Output 250 Amps 25 Volts DC CV Weld Output 250 Amps 25 Volts Auxiliary Power 10 000 Watts RANGER 250 GXT APPROXIMATE FUEL CONSUMPTION STICK TIG constant current 4 range settings WIRE FEED constant voltage 2 rang...

Page 19: ...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 250 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 t...

Page 20: ...maximum TIG Welding out 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 250 GXT WIRE FEED WELDING PROCESSES CONSTANT VOLTAGE The Innershield electrode recommended for use with the Ranger 250 GXT...

Page 21: ...e goes to high idle 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 TIG TIG MODULE WITH Yes HIGH Cold Press Amptrol WITH CONTACTOR KIT contactor closes CONTROL CABLE welding starts immediately AMPTROL WIRE FEED LN 15 No AUTO Cold Press gun trigger ACROSS the...

Page 22: ...20 240V 50 amps K802N Power Plug Kit Provides four 120V plugs rated at 20 amps each and one dual voltage 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 ca...

Page 23: ...TAW 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 Switch is pressed K936 3 Control Cable Connects TIG Module to Ranger 250 GXT Op...

Page 24: ... 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 to assure rapid and complete draining Remove the oil filler cap and dipstick Remove the...

Page 25: ...ocket tool to tighten the filter an additional 1 2 to 7 8 turn 5 Refill the crankcase with the specified amount of the recommended oil Reinstall the oil filler cap 6 Start the engine and check for oil filter leaks 7 Stop the engine and check the oil level If neces sary add oil to the upper limit mark on the dipstick AIR CLEANER AND OTHER MAINTENANCE Air Cleaner With normal operating conditions the...

Page 26: ...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 RANGER 250 GXT WARNING GASES FROM bATTERY can explode Keep sparks flame and cigarettes away from ba...

Page 27: ...BLE 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 Author...

Page 28: ...n 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 On PCB 7 Faulty P C Board 1 Idler switch on High Idle 2 Insufficient voltage present on idler solenoid terminals Voltage should be 12V to 14V DC 3 External load on welder or auxiliary power 4 Faulty wiring in solenoid circuit 5 Faulty idler ...

Page 29: ...gine shuts down Engine does not develop full power Engine is hard to start 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 n...

Page 30: ...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 ...

Page 31: ...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 ...

Page 32: ...F 3 DIAGRAMS F 3 RANGER 250 GXT ...

Page 33: ... I L I N E N G I N E A N D E M P T Y F U E L T A N K 2 1 0 0 2 0 8 0 4 2 1 0 3 3 6 2 3 6 2 4 1 0 2 7 1 0 7 8 N O T E C A S E F R O N T G R A P H I C S M A Y N O T M A T C H A L L C O D E S M20512 B CI CI R CU RCUIT IT B B R R EA EA KE KE R R S S 41 20 17 50 19 50 14 75 TRUCK UNDERCARRIAGE MOUNTING HOLES 24 86 2 6 7 22 29 88 CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK 21 00 20 80 42 10...

Page 34: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra l Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension l Isolez vous du travail et de la terre l Berühren Sie keine stromführenden Teile oder Elektroden mit ...

Page 35: ... und Entlüftung des Arbeitsplatzes l Mantenha seu rosto da fumaça l Use ventilação e exhaustão para remover fumo da zona respiratória l Turn power off before servicing l Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio l Débranchez le courant avant l entre tien l Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten l Não o...

Page 36: ...s 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 World s Leader in Welding and Cutting Products ...

Search results

Summary of Contents for RANGER 250 GXT (AU)

Reviews:

Related manuals for RANGER 250 GXT (AU)

Brands by name

Popular brands

Lincoln Electric RANGER 250 GXT (AU), Operator'S Manual

Search results

Summary of Contents for RANGER 250 GXT (AU)

Reviews:

Related manuals for RANGER 250 GXT (AU)

Brands by name

Popular brands