NOTES
RANGER GXT
Page 1: ...hought 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 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 We...
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: ...propriés 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...
Page 6: ...tion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number______________________________...
Page 7: ...rt 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 ________________________________________________________________________________ Accessorie...
Page 8: ...IONS Make Model Kohler CH20S Description 2 cylinder 4 Cycle Air Cooled Gasoline Engine Aluminum Alloy with Cast Iron Liners Electronic Ignition Operating Speed RPM High Idle 3700 Full Load 3500 Low Idle 2200 Displacement cu in cu cm 38 624 Capacities Fuel 12 Gal 45 4 L Lubricating Oil 2 0 Qts 1 9 L Horsepower 20 HP 3600 RPM Starting System 12VDC Battery Electric Start Group 58 Battery 435 cold Cra...
Page 9: ...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 prop...
Page 10: ...ated 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 GXT A 3 PRE OPERATION SERVICE READ the engine operating and maintenanc...
Page 11: ...n lifting the machine ADDITIONAL SAFETY PRECAUTIONS 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 r...
Page 12: ...WORK termi nal of the welder Position the welder Polarity switch to the desired polarity either DC or DC RANGER GXT Constant Current 250 Amps AC 25 Volts 250 Amps DC 25 Volts Constant Voltage 250 Amps DC 25 Volts 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 cur...
Page 13: ...18 75 50 150 100 50 23 15 46 30 15 125 88 225 175 90 38 27 69 53 27 175 138 350 275 150 53 42 107 84 46 300 225 600 450 225 91 69 183 137 69 Maximum Allowable Cord Length in ft m for Conductor Size Conductor size is based on maximum 2 0 voltage drop 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG AUXILIARY POWER The RANGER GXT can provide up to 10 000 watts of 120 240 volts AC single phase 60Hz power for c...
Page 14: ...ITHOUT 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 resolution TV s...
Page 15: ...d 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 4 Plug...
Page 16: ...50 AMP 240 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 120 240 VOLT PLUG NEMA TYPE 14 50 50 AMP 120 240 VOLT RECEPTACLE A 9 INSTALLATION RANGER GXT A 9 Connection of RANGER GXT to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and al...
Page 17: ...ceptacles 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 B 1 OPERATION RANGER 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 deta...
Page 18: ...r 5 09 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 GXT APPROXIMATE FUEL CONSUMPTION STICK TIG constant current 4 range settings WIRE FEED constant voltage 2 range se...
Page 19: ...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 t...
Page 20: ...he 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 GXT WIRE FEED WELDING PROCESSES CONSTANT VOLTAGE The Innershield electrode recommended for use with the RANGER GXT is N...
Page 21: ...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 High Cold Press gun trigger ACROSS the ARC LN 15 contactor closes has internal contacto...
Page 22: ...nt 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 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 c...
Page 23: ... 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 GXT Optional TIG Equipment K939 1 Docking Kit For Mounting the K930 2 TIG Mod...
Page 24: ...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 yellow cap f...
Page 25: ... socket 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 t...
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 GXT WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from batte...
Page 27: ...E 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 Authoriz...
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 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 soleno...
Page 29: ... power Engine will not crank or is hard to crank Engine 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 fil...
Page 30: ... 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: ...HE OUTPUT SELECTOR SWITCH TO THE WIRE FEED CV POSITION N C IF OPTIONAL REMOTE CONTROL IS USED PLACE THE LOCAL REMOTE SWITCH IN THE REMOTE POSITION ELECTRIC SHOCK can kill Do not operate with panels open Disconnect NEGATIVE Battery lead before servicing Do not touch electrically live parts WARNING MOVING PARTS can injure Keep guards in place Keep away from moving parts Only qualified personnel shou...
Page 32: ...RAMS F 3 RANGER GXT M20512 A 01 41 20 17 50 19 50 42 10 20 80 21 00 14 75 33 62 36 24 TRUCK UNDERCARRIAGE MOUNTING HOLES 24 86 2 6 7 22 10 28 10 78 29 88 CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK ...
Page 33: ...NOTES RANGER GXT ...
Page 34: ...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 35: ... 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 entretien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...
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 ...
