Lincoln Electric RANGER 250 GXT Operator's Manual
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Lincoln Electric RANGER 250 GXT Operator's Manual

Lincoln electric welder user manual
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RETURN TO MAIN MENU
IM921-D
®
RANGER 250 GXT
February, 2011
11400, 11420, 11493, 11667, 11668, 11736, 11737,
11792, 11973, 11799, 11800
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.
OPERATOR'S MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• 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

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Summary of Contents for Lincoln Electric RANGER 250 GXT

  • Page 1 RETURN TO MAIN MENU IM921-D ® RANGER 250 GXT February, 2011 11400, 11420, 11493, 11667, 11668, 11736, 11737, 11792, 11973, 11799, 11800 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However,...
  • Page 2 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. bE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY bY QUALIFIED INDIVIDUALS.
  • Page 3 SAFETY...
  • Page 4 SAFETY...
  • Page 5 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.
  • Page 6 Thank You...

  • Page 7: Table Of Contents

    Auxiliary Power While Welding, Standby Power Connections ...A-8 Premises Wiring ...A-9 ________________________________________________________________________________ Operation...Section b Safety Precautions ...B-1 General Description...B-1 Welder Controls Function and Operation ...B-1 Polarity, Range and Control Switch...B-2 Start in/Shutdown Instructions ...B-3 Starting the Engine...B-3 Safety Precautions ...B-3 Stopping the Engine ...B-3 Break-In Period ...B-3...

  • Page 8: Installation

    CH23S Aluminum Alloy with Cast Iron Liners, Electronic Ignition RATED OUTPUT @ 104°F (40°C)- WELDER RATED OUTPUT @ 104°F (40°C)- GENERATOR RECEPTACLES AND CIRCUIT bREAKERS RECEPTACLES AUXILIARY POWER CIRCUIT bREAKER (2) 120VAC Duplex (5-20R) Two 20AMP for Two Duplex Receptacle...

  • Page 9: Safety Precautions

    To prevent dangerous electric shock, other equip- ment to which this engine driven welder supplies power must: • be grounded to the frame of the welder using a grounded type plug, or be double insulated. Do not ground the machine to a pipe that carries explosive or combustible material.

  • Page 10: Vehicle Mounting

    Use caution as the electrolyte is a strong acid that can burn skin and damage eyes. ------------------------------------------------------------------------ This welder is shipped with the negative battery cable disconnected. Make sure that the Engine Switch is in the “STOP” position and attach the disconnected cable securely to the negative battery terminal before attempting to operate the machine.

  • Page 11: Angle Of Operation

    Listed below are copper cable sizes recommended for the rated current and duty cycle. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop.

  • Page 12: Location And Ventilation

    Also, locate the welder so that engine exhaust fumes are properly vented to an outside area.
  • Page 13 WELDER OPERATION 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.
  • Page 14 ELECTRICAL DEVICE USE WITH THE Ranger® 250 GXT. Type Resistive Capacitive Inductive Capacitive/Inductive The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the Ranger® 250 GXT. INSTALLATION TABLE lll Common Electrical Devices Heaters, toasters, incandescent light bulbs, electric range, hot pan, skillet, coffee maker.
  • Page 15 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 the 120V or 240V supply (not both at the same time). Also, the “Output Control” is set at “10” for maximum auxiliary power.

  • Page 16: Premises Wiring

    INSTALLATION Figure 1 CONNECTION OF Ranger® 250 GXT TO PREMISES WIRING WARNING Connection 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. RANGER®...

  • Page 17: Operation

    • Insulate yourself from work and ground • Always wear dry insulating gloves. • Always operate the welder with the hinged door closed and the side panels in place. • Read carefully the Safety Precautions page before operating this machine. Always follow...
  • Page 18 “ 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. Process Range Setting STICK/TIG 80 Max. (constant current) 130 Max. (4 range settings) 180 Max.

  • Page 19: Start In/Shutdown Instructions

    STARTING/SHUTDOWN INSTRUCTIONS STARTING THE ENGINE WARNING • Do not touch electrically live parts of electrode with skin or wet clothing. • Keep flammable material away. • Insulate yourself from work and ground. Wear eye, ear, and body protection. • Keep your head out of the fumes. •...

  • Page 20: Welding Process

    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”...

  • Page 21: Summary Of Welding Processes

    CONTROL CAbLE PROCESS USED STICK WIRE FEED, LN-25 WITH INTERNAL CONTACTOR TIG, TIG MODULE WITH WITH CONTACTOR KIT CONTROL CABLE, & AMPTROL WIRE FEED, LN-15 ACROSS the ARC (has internal contactor) When welding with MIG wire instead of self-shielded core wire, weld starts can be improved by setting the idle mode to “HIGH”.

  • Page 22: Accessories

    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 cable, 30 ft.

  • Page 23: Recommended Equipment

    RECOMMENDED EQUIPMENT STICK K704 Accessory Kit- (400 AMP Capacity) which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield K875 Accessory Kit- (150 AMP Capacity) WIRE FEED K449 LN-25 - Includes internal contactor for across the arc operation (no control cable). Provides “cold” electrode until gun trigger is pressed.

  • Page 24: Engine Oil Change/Refill Capacities

    SAFETY PRECAUTIONS WARNING 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.

  • Page 25: Air Cleaner And Other Maintenance

    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).

  • Page 26: Maintenance

    RANGER® 250 GXT WARNING cable from old battery first and connect to new bat- tery last. tery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated. first then connect negative lead to engine foot.

  • Page 27: Troubleshooting

    HOW TO USE TROUbLESHOOTING GUIDE 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 28 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) No welder output power or Auxiliary Power. Engine will not idle down to low speed. Engine will not go to high idle when attempting to weld. * Printed Circuit Board (PCB) 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.
  • Page 29 Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Engine will not go to high idle when using auxiliary power. Engine will not crank or is hard to crank. Engine shuts down. Engine does not develop full power. Engine is hard to start. 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.

  • Page 30: Wiring Diagrams

    DIAGRAMS RANGER® 250 GXT...
  • Page 31 DIAGRAMS RANGER® 250 GXT...
  • Page 32 DIAGRAMS RANGER® 250 GXT...

  • Page 33: Dimension Print

    DIMENSION PRINT RANGER® 250 GXT...
  • Page 34 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
  • Page 35 Spanish PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 36 • World's Leader in Welding and Cutting Products • • 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...

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