Lincoln Electric RANGER 250 GXT (AU) Operator's Manual
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Lincoln Electric RANGER 250 GXT (AU) Operator's Manual

Welding machine
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Operator's Manual
RANGER
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www.lincolnelectric.com/register
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10052-E
| Issue D ate Sept-13
© Lincoln Global, Inc. All Rights Reserved.
®
250 GXT (AU) Model
For use with machines having Code Numbers:
11689, 11741, 11796, 11803,
12099, 12194, 12205
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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Summary of Contents for Lincoln Electric RANGER 250 GXT (AU)

  • Page 1 Operator’s Manual ® RANGER 250 GXT (AU) Model For use with machines having Code Numbers: 11689, 11741, 11796, 11803, 12099, 12194, 12205 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. LINCOLN ELEC TRIC. DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Material Safety PLEASE EXAMINE CARTON AND EQUIPMENT FOR Data Sheet (MSDS) and the warning DAMAGE IMMEDIATELY...

  • Page 3: California Proposition 65 Warnings

    American Welding Society, P.O. Box 351040, Miami, Florida 33135 or ELECTRIC AND CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” MAGNETIC FIELDS MAY booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE DANGEROUS BE SURE THAT ALL INSTALLATION, OPERATION, 2.a.

  • Page 4: Electric Shock Can Kill

    SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the the gas and pressure used.

  • Page 6: Table Of Contents

    Additional Safety Precautions ..................A-5 Welding Operation Output, Auxiliary Power Receptacles, and Plugs .........A-6 Motor Starting and Extension Cord Length Table ..............A-6 Electrical Device Used with the Ranger 250 GXT (AU) ............A-7 Auxiliary Power While Welding, Standby Power Connections ..........A-8 ________________________________________________________________________________ Operation.........................Section B...

  • Page 7: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - Ranger® 250 GXT (AU) ( K2923-1) INPUT - GASOLINE ENGINE Description Operating Displacement Capacities Make/Model Starting Horsepower Speed (RPM) cu. in. System (cu.cm.) 2 cylinder High Idle 3700 12VDC 4 Cycle Kohler Battery Fuel: Air-Cooled CH23S, Electric Start 12 Gal (45.4 L) Gasoline...

  • Page 8: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS When this welder is mounted on a truck or trailer, itʼs frame must be electrically bonded to the metal frame of the vehicle. Use a #8 or larger copper wire connect- WARNING ed between the machine grounding stud and the Do not attempt to use this equipment until you frame of the vehicle.

  • Page 9: Vehicle Mounting

    INSTALLATION 3. Proper placement of the equipment on the trailer to FUEL insure stability side to side and front to back when being moved and when standing by itself while Fill the fuel tank with clean, fresh, lead-free gasoline. being operated or serviced. Observe fuel gauge while filling to prevent overfilling.

  • Page 10: Angle Of Operation

    INSTALLATION WELDING OUTPUT CABLES ADDITIONAL SAFETY PRECAUTION With the engine off, connect the electrode and work cables to the studs provided. These connections WARNING should be checked periodically and tightened if neces- • Lift only with equipment of sary. Loose connections will result in overheating of adequate lifting capacity.

  • Page 11: Location And Ventilation

    “CONTROL” at the welder. NOTE: The welding electrode is energized at all CONNECTION OF LINCOLN ELECTRIC times, unless an LN-25 with built-in contactor is used. WIRE FEEDERS If the output “CONTROL” is set below “3”, the LN-25 contactor may not pull in.

  • Page 12: Auxiliary Power

    INSTALLATION WELDER OPERATION MOTOR STARTING WELDER OUTPUT Most 1.5 hp AC single phase motors can be started if • Maximum Open Circuit Voltage at 3700 RPM is there is no load on the motor or other load connected 80 Volts RMS. to the machine, since the full load current rating of a •...

  • Page 13: Electrical Device Used With The Ranger 250 Gxt (Au

    DO NOT USE THESE DEVICES WITH A Ranger® 250 GXT (AU) The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the Ranger® 250 GXT (AU). RANGER® 250 GXT (AU)
  • Page 14 INSTALLATION AUXILIARY POWER WHILE WELDING Simultaneous welding and power loads are permitted by following Table I. The permissible currents shown assume that current is being drawn from either recep- tacle of 240V supply. Also, the “Output Control” is set at “10” for maximum auxiliary power. TABLE I SIMULTANEOUS WELDING AND POWER Output Selector...

  • Page 15: Operation

    OPERATION SAFETY PRECAUTIONS WELDER CONTROLS - FUNCTION AND OPERATION Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes ENGINE SWITCH important safety precautions, detailed engine The engine switch is used to Start the Engine, Select starting, operating and maintenance instructions, High Idle or Auto Idle while the engine is running, and and parts lists.

  • Page 16: Polarity Switch

    OPERATION “ 6-PIN CONNECTOR RANGE” SWITCH For attaching optional remote control equipment. The “Range” switch is used to select one of four amperage ranges with generous overlap for Stick/TIG LOCAL / REMOTE CONTROL SWITCH welding, or one Wire Feed welding range. (See Accessory Section For “K”...

  • Page 17: Start In/Shutdown Instructions

    OPERATION STARTING/SHUTDOWN INSTRUCTIONS STOPPING THE ENGINE STARTING THE ENGINE Remove all welding and auxiliary power loads and allow engine to run at low idle speed for a few minutes WARNING to cool the engine. • Do not touch electrically live parts Stop the engine by placing the Engine switch in the of electrode with skin or wet “OFF”...

  • Page 18: Welding Process

    OPERATION WELDING PROCESS SETTINGS FOR  1% THORIATED TUNGSTEN For any electrodes the procedures should be kept within TUNGSTEN RANGE SWITCH APPROXIMATE the rating of the machine. For electrode information see DIAMETER (in.) SETTINGS CURRENT RANGE the appropriate Lincoln publication. 80, 130, or 180 80 - 225 Amps 3/32 80 or 130...

  • Page 19: Summary Of Welding Processes

    OPERATION SUMMARY OF WELDING PROCESSES CONTROL ELECTRODE CABLE IDLE WHEN NOT TO START PROCESS USED MODE WELDING WELDING STICK AUTO Touch electrode to work. Welding starts immediately and engine goes to high idle. WIRE FEED, LN-25 WITH AUTO Cold Press gun trigger, LN-25 INTERNAL CONTACTOR contactor closes.

  • Page 20: Accessories

    ACCESSORIES OPTIONAL EQUIPMENT (Field Installed) K875 Accessory Kit - For Stick welding. Includes 20ft.(6.1m)#6 electrode cable with lug. 15ft.(4.6m)#6 work K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR cable with lugs, headshield, filter plate, work clamp, elec- SMALL WELDERS - For road, off-road and in-plant trode holder and sample pack of mild steel electrode.

  • Page 21: Recommended Equipment

    ACCESSORIES RECOMMENDED EQUIPMENT OPTIONAL TIG EQUIPMENT: STICK K939-1 Docking Kit - For Mounting the K930-2 TIG Module on top of the Ranger® 250 GXT (AU). K704 Accessory Kit- (400 AMP Capacity) which includes: K937-45 Control Cable Extension - Allows TIG Module to be operated at distances up to 200ft.

  • Page 22: Maintenance

    MAINTENANCE SAFETY PRECAUTIONS CAUTION WARNING Make certain that the oil filler cap is securely tight- ened after checking or adding oil. If the cap is not Have qualified personnel do the maintenance tight, oil consumption can increase significantly work. Turn the engine off before working inside which may be evidenced by white smoke coming the machine.
  • Page 23 MAINTENANCE Use 4-stroke motor oil that meets or exceeds the AIR CLEANER AND OTHER MAINTENANCE requirements for API service classification SG or SH. Always check the API SERVICE label on the oil con- • Air Cleaner - With normal operating conditions, the tainer to be sure it includes the letters SG or SH.

  • Page 24: Engine Adjustments

    MAINTENANCE ENGINE ADJUSTMENTS WARNING GASES FROM BATTERY can explode. OVERSPEED IS HAZARDOUS • Keep sparks, flame and cigarettes away from battery. To prevent EXPLOSION when: WARNING • INSTALLING A NEW BATTERY - disconnect negative cable from old battery first and connect to new bat- tery last.

  • Page 25: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE 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.
  • Page 26 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION No welder output power or Auxiliary 1. Open in miscellaneous leads. Power. 2. Open lead in flashing or field circuit. 3. Faulty rotor. 4.
  • Page 27 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Engine will not go to high idle when No voltage signal from the using auxiliary power. current sensor. Auxiliary power load less than 100 to 150 watts.
  • Page 28 WIRING DIAGRAM Enhanced Diagram RANGER® 250 GXT (AU)
  • Page 29 DIAGRAMS RANGER® 250 GXT (AU)
  • Page 30 DIMENSION PRINT RANGER® 250 GXT (AU)
  • Page 31 DIAGRAMS RANGER® 250 GXT (AU)
  • Page 32 NOTES RANGER® 250 GXT (AU)
  • Page 33 NOTES RANGER® 250 GXT (AU)
  • Page 34 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
  • Page 35 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
  • Page 36 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

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