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RETURN TO MAIN MENU
IM856
RANGER
GXT
™
May, 2005
For Machines with Code Number 11154
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 thought-
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.
OPERATOR'S MANUAL
Copyright © 2005 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 GXT IM856
- Page 1 RETURN TO MAIN MENU IM856 RANGER ™ May, 2005 For Machines with Code Number 11154 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 ...
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Page 2: California Proposition 65 Warnings
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: Electric Shock Can Kill
ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. - Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent 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.
- 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 The code number is especially important when identifying the correct replacement parts. - 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.
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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: Technical Specifications
Kohler Engine. CH20S Aluminum Alloy with Cast Iron Liners, Electronic Ignition RATED OUTPUT @ 104°F (40°C)- WELDER RATED OUTPUT @ 104°F (40°C)- GENERATOR HEIGHT WIDTH 30 in.** 21.5 in. 762 mm 546 mm 1. Output rating in watts is equivalent to volt - amperes at unity factor.Output voltage is within +/-10% at all loads up to rated capacity. -
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: Pre-Operation Engine Service
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: Auxiliary Power
AUXILIARY POWER The RANGER GXT can provide up to 10,000 watts of 120/240 volts AC, single phase 60Hz power for con- tinuous use, and up to 11,000 watts of 120/240 volts AC, single phase 60Hz power peak use. The front of the machine includes three receptacles for connecting the AC power plugs;... - Page 14 ELECTRICAL DEVICE USE WITH THE RANGER GXT. Type Resistive Capacitive Inductive Capacitive/Inductive The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect- ed to the RANGER GXT. INSTALLATION TABLE lll Common Electrical Devices Heaters, toasters, incandescent light bulbs, electric range, hot pan, skillet, coffee maker.
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Page 15: Auxiliary Power While Welding
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
CONNECTION OF RANGER GXT TO PREMISES WIRING 240 VOLT POWER 240 Volt 60 Hz. COMPANY 3-Wire Service METER 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... -
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: Pin Connector
“ 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) OPERATION SUMMARY OF WELDING PROCESSES ELECTRODE IDLE WHEN NOT MODE WELDING AUTO... -
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 which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield 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. -
Page 24: Maintenance
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: Engine Adjustments
• CONNECTING A BATTERY CHARGER - Remove bat- tery from welder by disconnecting negative cable first, then positive cable and battery clamp. When rein- stalling, connect negative cable last. Keep well venti- lated. -
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 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 solenoid. 6. Faulty P.C. Board.
- 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 DIAGRAMS RANGER GXT...
- Page 31 DIAGRAMS RANGER GXT...
- Page 32 DIAGRAMS RANGER GXT...
- Page 33 NOTES RANGER 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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