RANGER GXT ™ IM879 March, 2006 For Machines with Code Number 11269 This manual covers equipment which is no longer in production by The Lincoln Electric Co. Specifications and availability of optional features may have changed. 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.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. 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. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY 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. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv SAFETY 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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ........................................................................................................A-2 Machine Grounding ...................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Ranger GXT (K2382-2 ) INPUT - GASOLINE ENGINE Make/Model Description Kohler CH20S 2 cylinder 4 Cycle Air-Cooled Gasoline Engine. Aluminum Alloy with Cast Iron Liners, Electronic Ignition Horsepower Operating Displacement Speed (RPM) cu. in. (cu.cm.) High Idle 3700 20 HP @ 3600 RPM Full Load 3500 Starting System Capacities 12VDC Battery Fuel: Electric Start 12 Gal (45.4 L) Group 58 Lubricating Oil: Battery 2.0 Qts. (1.
A-2 A-2 INSTALLATION SAFETY PRECAUTIONS WARNING 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 maintenance instructions, and parts lists. -----------------------------------------------------------------------ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing.
INSTALLATION A-3 3. Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself while being operated or serviced. FUEL Fill the fuel tank with clean, fresh, lead-free gasoline. Observe fuel gauge while filling to prevent overfilling. 4. Typical conditions of use, i.e., travel speed; roughness of surface on which the trailer will be operated; environmental conditions. 5.
A-4 A-4 INSTALLATION WELDING OUTPUT CABLES ADDITIONAL SAFETY PRECAUTIONS With the engine off, connect the electrode and work cables to the studs provided. These connections should be checked periodically and tightened if necessary. Loose connections will result in overheating of the output studs. When welding at a considerable distance from the welder, be sure you use ample size welding cables. Listed below are copper cable sizes recommended for the rated current and duty cycle.
A-5 INSTALLATION A-5 • LOCATION / VENTILATION The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid heated air coming out of the welder recirculating back to the cooling air inlet. Also, locate the welder so that engine exhaust fumes are properly vented to an outside area. STACKING RANGER GXT machines cannot be stacked. CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off welder before making any electrical connections.
A-6 A-6 INSTALLATION WELDER OPERATION 120/240 VOLT DUAL VOLTAGE RECEPTACLE 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 GXT is 100%.
A-7 A-7 INSTALLATION TABLE lll ELECTRICAL DEVICE USE WITH THE RANGER GXT. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent light bulbs, electric range, hot pan, skillet, coffee maker. NONE Capacitive TV sets, radios, microwaves, appliances with electrical control. Voltage spikes or high voltage regulation can cause the capacitative elements to fail. Surge protection, transient protection, and additional loading is recommended for 100% fail-safe operation.
A-8 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 the 120V or 240V supply (not both at the same time). Also, the “Output Control” is set at “10” for maximum auxiliary power. TABLE I SIMULTANEOUS WELDING AND POWER Output Selector Setting * Permissible Power Watts (Unity Power Permissible Auxiliary Current in Amperes Factor) @ 120V *-or- @ 240V Max.
A-9 A-9 INSTALLATION Figure 1 CONNECTION OF RANGER GXT TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 60 Hz. 3-Wire Service 120 VOLT COMPANY 120 VOLT METER NEUTRAL BUS N LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.
B-1 OPERATION 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 maintenance instructions, and parts lists. -----------------------------------------------------------------------ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing.
B-2 “ OPERATION 6-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 STICK/TIG (constant current) (4 range settings) WIRE FEED (constant voltage) (2 range setting) Range Setting B-2 Current Range 80 Max. 130 Max. 180 Max. 250 Max.
B-3 B-3 OPERATION STARTING/SHUTDOWN INSTRUCTIONS STARTING THE ENGINE STOPPING THE ENGINE Remove all welding and auxiliary power loads and allow engine to run at low idle speed for a few minutes to cool the engine. WARNING • Do not touch electrically live parts of electrode with skin or wet clothing. 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.
B-4 B-4 OPERATION WELDING PROCESS SETTINGS FOR 1% THORIATED TUNGSTEN For any electrodes the procedures should be kept within the rating of the machine. For electrode information 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” switch to the desired polarity.
B-5 B-5 OPERATION SUMMARY OF WELDING PROCESSES CONTROL CABLE USED IDLE MODE ELECTRODE WHEN NOT WELDING STICK No AUTO Hot Touch electrode to work. Welding starts immediately and engine goes to high idle. WIRE FEED, LN-25 WITH INTERNAL CONTACTOR No AUTO Cold Press gun trigger, LN-25 contactor closes. Welding starts immediately and engine goes to high idle. Note: Output Control must be set above “3”.
C-1 OPTIONAL EQUIPMENT ACCESSORIES (Field Installed) K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.) Order K957-1 Trailer K958-1 Ball Hitch K958-2 Lunette Eye Hitch K959-2 Fender & Light Kit K965-1 Cable Storage Rack K1737-1 FOUR WHEEL ALL-TERRAIN UNDERCARRIAGE - For moving by hand at construction sites.
C-2 ACCESSORIES C-2 RECOMMENDED EQUIPMENT STICK Optional TIG Equipment: K704 Accessory Kit which includes: K939-1 Docking Kit - For Mounting the K930-2 TIG Module on top of the RANGER GXT. • Electrode Holder & Cable • Work Clamp & Cable • Headshield K937-45 Control Cable Extension - Allows TIG Module to be operated at distances up to 200ft. from the power source. Available in 45ft. (13.7m).
D-1 D-1 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 maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. Do not put your hands near the engine cooling blower fan.
D-2 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 container to be sure it includes the letters SG or SH. AIR CLEANER AND OTHER MAINTENANCE • Air Cleaner - With normal operating conditions, the maintenance schedule for cleaning and re-oiling the foam pre-filter is every 25 hours and replacement of the air cleaner filter every 100 hours.
D-3 D-3 MAINTENANCE ENGINE ADJUSTMENTS WARNING GASES FROM BATTERY can explode. • Keep sparks, flame and cigarettes away from battery. OVERSPEED IS HAZARDOUS To prevent EXPLOSION when: • INSTALLING A NEW BATTERY - disconnect negative cable from old battery first and connect to new battery last. WARNING The maximum allowable high idle speed for this machine is 3750 RPM, no load. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed.
E-1 TROUBLESHOOTING E-1 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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) No welder output power or Auxiliary Power. POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION 1. Open in 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. Engine will not idle down to low speed.
E-3 E-3 TROUBLESHOOTING 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. POSSIBLE CAUSE 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.
5L 230 1 RANGER GXT 210 210 4 STARTER SOLENOID U 3 4 P5 CR1 R R J5 209A 209A REGULATOR STARTER AC B- V 1 2 212A 211 CB5 20A 211 U = BLUE V = VIOLET 1 5 FUEL GAUGE 4 8 FUEL SHUTOFF SOLENOID 50A CB1 50A 6B 1 5 1 3 PCB1/J2 2 4 A A3 6 6 12 6F 3 E 2 1 7 + - D1 B A4 6E 3D 5 5B J3 120V 7 S1 5D 5M W1 W2 254 6 3 + 9 3 1 4 2 J2 77A OUTPUT CONTROL CW 77B 76A R1 76B J1-1 PCB2 GND-K 77A 76A J1-4 J1-8 77B 76B LOCAL REMOTE SWITCH 1
ELECTRODE RANGER GXT IF OPTIONAL REMOTE CONTROL IS USED, PLACE THE “LOCAL/REMOTE” SWITCH THE “REMOTE” POSITION. N.C. IN USE POLARITY SWITCH TO SET FOR DESIRED ELECTRODE POLARITY. POSITION THE OUTPUT SELECTOR SWITCH TO THE WIRE FEED (CV) POSITION. N.B. DIAGRAMS M20597 08/20/2004 TO WORK WORK CLIP LEAD WELDING CABLE MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. ELECTRODE CABLE TO WORK REMOTE CONTROL (OPTIONAL) LN-25 OR LN-15 WIRE FEEDER Keep guards in place.
RANGER GXT 42.10 20.80 24.86 21.00 41.20 TRUCK/UNDERCARRIAGE MOUNTING HOLES 2.6 17.50 19.50 14.75 CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK.. 10.27 10.78 29.88 33.62 36.24 DIAGRAMS M20512 B NOTE: CASEFRONT GRAPHICS MAY NOT MATCH ALL CODES. CIRCUIT BREAKERS 7.
NOTES RANGER GXT
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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