Lincoln Electric 225 GXT Welder User Manual
Contents
1. RANGER 225 GXT LINCOLN E 5 RANGER 225 GXT LINCOLN 5 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENC O Chinese Korean Do nottouch 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 d a del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra ARPORABR xiSHl t 7 5nfdcomntoc t e amp etti B cIemmc FRE ez SUEZ xe zz su e zial Yall Gd ge l Areal d Ah ach AA ua aal Aa Lie Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammabl2. Insulate yourself from work and ground Wear eye ear and body protection 23 Keep your head out of the fumes DA Be sure all Pre Operation Maintenance has been per formed Also read the Engine Owner s Manual before starting for the first time Use ventilation or exhaust to remove fumes from breathing zone Remove all loads connected to the AC power recepta cles Use the choke control as follows KOHLER ENGINE Always pull the choke control out when starting the engine cold warm or hot Turn the engine switch to the start CH position and crank the engine until it starts Release the switch as soon as the engine starts slowly return the choke control to the full in position choke open and turn the switch to the Auto det 4573 lt position Do not turn the switch to the start position while the engine is running because this will cause damage to the ring gear and or starter motor After running at high engine speed for 10 14 seconds the engine will go to low idle Allow the engine to warm up by letting it run at low idle for a few minutes OPERATION B 3 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 Stop the engine by placing the Engine switch in the OFF position A fuel shut off valve is not required on the RANGERG 225 GXT because the fuel tank is mounted below t
3. SHASNNN ALIAVO ILON 7 lNOH33SVO 1437 NO IVNIIAH3 L MIYOS 401 7 usus S 1N3NOdWOO 3NION3 HOLVNH3ITV TH3HMA TH GION310S Sons bg aunssaud ualuvis ov ba ov ANNOYS HOLVIND3H anaon 1 044 8 q NOILINOI SSOHO fusiuvis Enhanced L HV HONG J E EA EM 1 NNOO 33S m 310078 TVNIAH3 L LOA 2L EI 602 gt Lie 12 lNOHd3SVO LH VEL giz 09 3S vee vez v DIAGRAMS NO anis EICH 19 1303 1 0 338 1331 60 NO WOLLOS GION31OS TlOHLNOO LIN9HI9 095010 X Andino XIXT X WIS X X OLN jio es NOILISOd 30041911 04 NI NMOHS ZS HOLIMS ALIHV1Od HOLIMS 13n4 3160440 NI GIOHOL SNYNL 9 SQv31 1X9 Scc X X 5 RANGER 225 LINCOLN E 2 99ZOZIN A9 4333 SHIM JHL OL HOL
4. FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 3 The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and applicaiton involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts Shielding gases u
5. Optional Equipment EIDA iji eruit ederent rre d d R HURA ET ue M e Eu Routine Engine Maintenance sisi ne a EE EEN Ee Cl EE Battery Engine Maintenance Parts 1i tice st iron Erbe ker n Troubleshooting eren uio eroe eorr uer reni ecu nee cn Pn a e con usan pa ARA MEKE RA How to Use Troubleshooting Guide aaa Troubleshooting Guide ss Wiring Diagrams amp Dimension Print sise Wiring and Connection Diagrams Dimension PRIN EE calde P 581 vi 1 INSTALLATION TECHNICAL SPECIFICATIONS RANGER 225 GXT K2733 1 Make Model Horsepower 2 cylinder 4 Cycle Air Cooled Gasoline Engine Aluminum Alloy with Cast Iron Liners Electronic Ignition INPUT GASOLINE ENGINE Operating Displacement Speed RPM cu in cu cm High Idle 3700 23 HP Full Load 3500 41 1 674 3600 RPM Low Idle 2200 A 1 Starting Capacities System 12VDC Battery Electric Start Group 58 Battery 435 cold Cranking Amps Fuel 12 Gal 45 4 L Lubricating Oil 2 0 Qis 1 9 L RATED OUTPUT 9 104 F 40 C WELDER Welding Output AC Constant Current 225A 25V 10096 DC Constant Current 210A 25V 10096 DC Constant Voltage 2004 20V 10096 RA
6. iary power INSTALLATION A 6 120 240 VOLT DUAL VOLTAGE RECEPTACLE The 120 240 volt receptacle can supply up to 38 amps of 240 volt power to a two wire circuit up to 38 amps of 120 volts power from each side of a three wire circuit up to 76 amps total Do not connect the 120 volt circuits in parallel Current sensing for the automatic idle feature is only in one leg of the three wire circuit as shown in the following column GND 120V 240V Y A 120 V Y Current Sensing for Automatic Idle Receptacle viewed from front of Machine 120 V DUPLEX RECEPTACLES The 120V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current load through the associated receptacle MOTOR STARTING Most 1 5 hp AC single phase motors can be started if there is no load on the motor or other load connected to the machine since the full load current rating of a 1 5 hp motor is approximately 20 amperes 10 amperes for 240 volt motors The motor may be run at full load when plugged into only one side of the duplex receptacle Larger motors through 2 hp can be run provided the receptacle rating as previously stated is not exceeded This may necessitate 240V operation only RANGER 225 GXT Extension Cord Length Recommen
7. sion resistance Low sway suspension gives outstanding stability with manageable tongue weight Wheels bearings are packed with high viscosity high pressure low washout Lubriplate grease Features a Duo Hitch 2 Ball Lunette Eye combi nation hitch Order K2635 1 Trailer K2639 1 Fender and Light Kit K2640 1 Cable Rack K1737 1 FOUR WHEEL ALL TERRAIN UNDER CARRIAGE For moving by hand at construction sites Heavy duty puncture resistant pneumatic tires K1770 1 UNDERCARRIAGE FACTORY For mov ing by hand on a smooth surface One or two gas cylinders can be mounted on the rear of the undercar riage with the installation of K1745 1 Cylinder Holder s Heavy duty puncture resistant pneumatic tires and front caster K1745 1 WELDING GAS CYLINDER LPG TANK HOLDER Holds Welding Gas Cylinder for use on K1770 1 Undercarriage One or two may be installed on an undercarriage K1788 1 ROLL CAGE Gives added damage protection Attaches to K1737 1 K1770 1 and K957 1 K886 2 Canvas Cover To protect the RANGER 225 GXT when not in use Made from attractive red canvas material which is flame retardant mildew resistant and water repellent 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 K704
8. tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseig
9. s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas SNRMPAN ERVUALKEE CRRBTFEL UTES AGFA Ez e Gel 452 c t UN al ass e Aalt Gul Al iall AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENC O Japanese Es FR Chinese Ss LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR t3 TEE ENEE CEA RA E TERLCTF U TMHORSME HET FEU R WE II ER HE HI BI KE RE JE BE 89 Bi BI BL R KE ER 8 F8 88 354143551 SE EROR 2 KT o SSE AIBAIE FAS Pe spec Jali Gaz kal QU gll ud al l n Gail lates canis l LINCOLN 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
10. AWAY PACEMAKER 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 amp 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 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 FOR ENGINE powered equipment Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 cm 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 23 ELECTRIC AND xwa MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 1 Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact w
11. Accessory Kit Includes 35 ft 10 7m 2 0 AWG elec trode cable 30 ft 9 1m 2 0 AWG work cable headshield with No 12 filter GC300 work clamp and Cooltong 300 electrode holder Cables are rated at 300 amps 10096 duty cycle K875 Accessory Kit For Stick welding Includes 20ft 6 1m 6 electrode cable with lug 15ft 4 6m 6 work cable with lugs headshield filter plate work clamp elec trode holder and sample pack of mild steel electrode 150 amp capacity K1898 1 Spark Arrester Kit Attaches between muffler and exhaust elbow Virtually eliminates spark emissions K1690 1 GFCI RECEPTACLE KIT Includes one UL approved120V ground fault circuit interrupter duplex type receptacle with cover and installation instructions Replaces the factory installed 120V duplex receptacle Each receptacle of the GFCI Duplex is rated at 20 Amps the maximum total current from the GFCI Duplex is limit ed to the 20 Amps Two kits are required K1816 1 FULL KVA ADAPTER KIT Plugs into the 120 240V NEMA 14 50R receptacle on the case front which accepts 4 prong plugs and converts it to a NEMA 6 receptacle which accepts 3 prong plugs T12153 9 Full KVA Power Plug One dual voltage plug rated at 120 240V 50 amps RANGER 225 GXT LINCOLN 5 2 RECOMMENDED EQUIPMENT STICK K704 Accessory Kit 400 AMP Capacity which includes Electrode Holder amp Cable Work Clamp amp Cable Headshield K875 Accessory
12. Additional Safety Precautions High Altitude Muffler Outlet Pipe Location and Ventilation LACKING castrate tenn Connection of Wire Feeders Connection of Tig Module Additional Safety Precautions Welding Operation Output Auxiliary Power Receptacles and Plugs Motor Starting and Extension Cord Length Table Electrical Device Used with the Ranger 10 000 Auxiliary Power While Welding Standby Power Connections Premises IE Operation ied ina Ea diw kax kaw Di k buk ka ea x xana kunka k ku k ra a rw a k xay Van cM Safety Precautions EEN ENEE Welder Controls Function and Operation Range Polarity Control Switch and Fuel Consumption Start in Shutdown Instruchons ns Starting the anie Iii eR IRE Safety Precautions Stopping ou meii DD DD Dd Break Im Penodi enaid deda MN eeepc Gil freto Welding Process renes Stick Constant Current Welding TIG Constant Current Welding Wire Feed Welding Processes Constant Voltage Ate GOUGING Summary of Welding IAC COSS OMICS KA Ea RAN Hu RA E RAA na K scene ABD
13. by hand until the gasket contacts the filter mounting base then use an oil fil ter socket tool to tighten the filter an additional 1 2 to 7 8 turn 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 the maintenance schedule for cleaning and re oiling the foam pre filter is every 25 hours and replace ment of the air cleaner filter every 100 hours More frequent servicing is required with dusty operating conditions Refer to the maintenance section of the Engine Owner s Manual for more information Refer to the maintenance section of the Engine Owner s Manual for the maintenance schedule spark plug servicing cooling system servicing and fuel filter replacement Blow out the machine with low pressure air period ically In particularly dirty locations this may be required once a week Output Ranger Selector and Polarity Switches Switch contacts should not be greased To keep contacts clean rotate the switch through its entire range frequently Good practice is to turn the han dle from maximum to minimum setting twice each morning before starting to weld RANGER 225 GXT LINCOLN 5 D 3 ENGINE ADJUSTMENTS OVERSPEED I
14. following table ELECTRODE SETTING CURRENT RANGE DC electrode positive 1 8 30 60 Amps 5 32 90 150 Amps 3 6 150 250 Amps RANGER 225 GXT LINCOLN 5 B 5 OPERATION SUMMARY OF WELDING PROCESSES ELECTRODE WHEN NOT PROCESS WELDING WIRE FEED LN 25 WITH INTERNAL CONTACTOR TIG TIG MODULE WITH WITH CONTACTOR KIT CONTROL CABLE amp 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 RANGER 225 GXT LINCOLN TO START WELDING Touch electrode to work Welding starts immediately and engine goes to high idle Press gun trigger LN 25 contactor closes Welding starts immediately and engine goes to high idle Note Output Control must be set above 3 Press Amptrol contactor closes welding starts immediately Press gun trigger LN 15 contactor closes Welding starts immediately and engine goes to HIGH Idle Note Output Control must be set above 3 C1 ACCESSORIES 1 OPTIONAL EQUIPMENT Field Installed K2635 1 SMALL TWO WHEEL ROAD TRAILER WITH DUO HITCH For heavy duty road off road plant and yard use Includes pivoting jack stand safety chains and 13 wheels Overall width 60 Stiff 120 welded rectangu lar steel tube frame construction is phosphate etched and powder coat painted for superior rust and corro
15. hands hair cloth ing and tools away from gears fans and all other moving parts when starting operating or repairing the equipment Routine Maintenance end of each day s use refill the fuel tank to minimize moisture condensation in the tank Running out of fuel tends to draw dirt into the fuel System Also check the crankcase oil level and add oil if indicated CAUTION Make certain that the oil filler cap is securely tight ened after checking or adding oil If the cap is not tight oil consumption can increase significantly which may be evidenced by white smoke coming from the exhaust OIL Maintenance schedule for changing the oil and Kohler CH23S oil filter after break in Oil Filter 200 Hrs The above schedule is for normal operating condi tions More frequent oil changes are required with dusty high temperature 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 7 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 from the oil drain valve and attach the flexible drain tube supplied with the machine Push in and twist the drain valve counterclockwise Pull the valve out and drain the
16. la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product by Lincoln Electric We want you Tha OU to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such informat
17. oil into a suitable contain er Close the drain valve by pushing in and twisting clockwise Replace the yellow cap Refill to the upper limit mark on the dipstick with the recommended oil Tighten the oil filler cap securely ENGINE OIL REFILL CAPACITIES Without oil filter replacement 1 7qt 1 6 liter Kohler With oil filter replacement 2 0qt 1 9 liter Kohler RANGER 225 GXT LINCOLN 5 D 2 MAINTENANCE D 2 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 See Engine Owner s Manual for more specific informa tion on oil viscosity recommendations Wash your hands with soap and water after handling used oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station recycling center for reclamation Do not throw it in the trash pour it on the ground or down a drain OIL FILTER CHANGE mk Drain the engine oil 2 Remove the oil filter and drain the oil into a suitable container Discard the used oil filter e Clean the filter mounting base and coat the gasket of the new oil filter with clean engine oil 4 Screw on the new oil filter
18. Amps 3 32 80 or 130 50 180 Amps 1 16 80 45 120 Amps For AC TIG Welding the 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 210DC 225AC Amp setting The output may exceed the rating of the RANGER 225 GXT WIRE FEED WELDING PROCESSES CONSTANT VOLTAGE The Innershield electrode recommended for use with the 225 GXT is 211 The elec trode sizes and welding ranges that can be used with the RANGER 225 GXT are shown in the following table Diameter Wire Speed Approximate in Range In Min Current Range 80 110 75A to 120A 70 130 120A to 170A 40 90 125A to 210A The RANGER 225 GXT is recommended for limited MIG welding GMAW gas metal arc welding The recommended electrodes are 030 and 035 L 50 and L 56 They must be used with a blended shield ing gas such as C25 7596 Argon 2596 The welding ranges that can be used with the RANGER 225 GXT are shown in the following table Diameter Wire Speed Range In Min Approximate Current Range 75 300 50A to 130A 100 250 90A to 175A ARC GOUGING The RANGER 225 GXT can be used for limited arc gouging Set the Range switch to adjust output current to the desired level for the gouging electrode being used according to the ratings in the
19. CE OVERCURRENT PROTECTION PREMISES DISCONNECT AND SERVICE 40 AMP GROUND OVERCURRENT 240 VOLT PROTECTION DOUBLE POLE 50 AMP 120 240 CIRCUIT VOLT PLUG 240 VOLT BREAKER NEMA TYPE 14 50 20 50 AMP 120 240 VOLT Wi T NOTE No 6 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS WARNING Connection of RANGER 225 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 225 GXT LINCOLN 5 B 1 OPERATION 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 detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing 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 these and any other safety procedures included in this manual and in the Engine Instruction Manual GENERAL DESCRIPTION The RANGER 225 GXT is a twin cylinder gasoline driven multiprocess arc welder an
20. IMS 0123136 119110 JHL NOILISOd ALIH V TOd 1004193713 138 OL HOLIMS ALlHY10d ISN 40 319A9 ALNG HOS 03715 38 LSNW 318V9 ONIGTAM 318 0 30081 0819 OL OL 300419373 MHOM OL 4HOM 4230333 SUNT HO 9 DIAGRAMS d3d13M ANIDNA jueuidinbe siy 10 sued jou oq e jeuuosjed AUO e sued deay e pee Moyeg 3ALLVO3N 12euuoosiq e eoe d ui e uedo sjaued jou e ainful ueo I US HOOHS 91419312 ONINHVM V NOLLO3NNOO SSOHOV SI N 1l HO 9 2 882 SZZ MYVING TSM 3SVHd H39NVH 0000 H395NVH LX9 S22 H39NVH F 2 RANGER 225 GXT LINCOLN E DIMENSION PRINT F 3 F 3 ELS LZIN SATOH ONILNNON 9 53000 HOLVIN LON AVIN SOIHdYH9 1NOH33S VO ALON 0 17 Mut ul 1304 ONY 3NION3 NI TIO ALIAVHO 40 H31N30 1
21. 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 Includes gas solenoid K1870 1 LN 15 Across the Arc Model Magnum Gun and Magnum Gun Connector Kit are required for gas shielded welding Innershield Gun is required for gasless welding K126 2 Magnum 350 Innershield Gun K1802 1 Magnum 300 MIG Gun for LN 25 K470 2 Magnum 300 MIG Gun for LN 15 K1500 1 Gun Receiver Bushing for LN 15 amp K126 2 TIG Magnum TIG Torch K1783 4 TIG Torch KP509 Magnum Parts Kit and Argon Gas K930 2 TIG Module Provides high frequency and shield ing gas control for AC and DC GTAW TIG welding applica tions Its compact case is designed foe easy carrying com plete with a handle High frequency bypass is built in Requires K938 1 Contactor Kit K936 4 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 4 Control Cable Connects TIG Module to RANGER 225 GXT ACCESSORIES Optional TIG Equipment K939 1 Docking Kit For Mounting the K930 2 TIG Module on top of the RANGERO 225 GXT K937 45 Control Cable Extension Allows TIG Module to be operated at distances up to 200ft from the power source Available 451 13 7m K814 Arc Start Switch Plasma K1580 1
22. Pro Cut 55 Requires Full KVA Adapter K1816 1 RANGER 225 GXT LINCOLN 5 D 1 MAINTENANCE D 1 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 Always use the greatest care when working near moving parts Do not put your hands near the engine cooling blower fan problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves e ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 2 MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing away from moving parts See additional warning information throughout this operator s manual and the Engine manual as well Read the Safety Precautions in the front of this manual and the engine instruction manual before working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep
23. RANGER 225 pecember 200 For Machines with Code Number 11522 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 150 9001 e EM gt S LI by Inc Designed and Manufactured Under a Re LI NCOLN e Copyright O 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 WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN
24. S HAZARDOUS 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 Severe personal injury and damage to the machine can result if operated at speeds above maximum Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop SLIP RINGS A slight amount of darkening and wear of the slip rings and brushes is normal Brushes should be inspected when general overhaul is necessary If brushes are to be replaced clean slip rings with a fine emery paper CAUTION Do not attempt to polish slip rings while engine is running MAINTENANCE D 3 A WARNING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new battery last 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 USING A BOOSTER connect positive lead to battery first then connect negative lead to engine foot battery BATTERY ACID CAN BURN EYES AND SKIN Wear gloves and eye protection and be careful when working near battery F
25. T PUT Control settings below 5 may reduce arc stabili ty For best overall welding performance set the RANGE Switch to the lowest setting and the OUT PUT Control near the maximum to achieve the desired welding current RANGE SETTING TYPICAL CURRENT RANGE ELECTRODE SIZE 3 32 90 MAX 40 TO 90 AMPS 145 MAX 1 8 The RANGER 225 GXT can be used with a broad range of AC and DC stick electrodes See Welding Tips 1 included with the RANGER 225 GXT for electrodes within the rating of this unit and recom mended welding currents of each 70 TO 145 AMPS 120 TO 210 DC 225 AC AMPS TIG CONSTANT CURRENT WELDING The RANGER 225 GXT can be used in a wide variety of AC and DC Tungsten Inert Gas TIG welding applications for AC TIG Welding up to 200 amps and DC TIG welding up to 210 amps The 930 TIG Module installed on a RANGER 225 GXT provides high frequency and shielding gas control for AC and DC GTAW TIG welding processes The TIG Module allows full range output control When using the RANGER 225 GXT for AC TIG welding of alu minum the following settings and electrodes are recommended APPROXIMATE CURRENT RANGE 80 or 130 100 300 Amps 80 45 140 Amps 80 45 100 Amps TUNGSTEN DIAMETER in RANGE SWITCH SETTINGS OPERATION B 4 SETTINGS FOR 196 THORIATED TUNGSTEN TUNGSTEN DIAMETER in RANGE SWITCH SETTINGS APPROXIMATE CURRENT RANGE 1 8 80 130 or 180 80 225
26. TED OUTPUT 10492 40 C GENERATOR Auxiliary Power 1 9 000 Watts Continuous 60 Hz AC 10 500 Watts Peak 60 Hz AC 120 240 Volts RECEPTACLES AND CIRCUIT BREAKERS 2 120VAC Duplex 5 208 1 120 240VAC Dual Voltage Full KVA 14 50R HEIGHT Two 20AMP for Two Duplex Receptacle 1 40AMP for Dual Voltage 2 pole PHYSICAL DIMENSIONS WIDTH DEPTH 20AMP for Engine Battery Charging Circuit WEIGHT 30 00 in 762 0 mm Top of enclosure add 6 00 152mm for exhaust 42 25 in 1073 0 mm 21 50 in 546 0 mm ENGINE COMPONENTS 567 lbs 257kg LUBRICATION VALVE LIFTERS FUEL SYSTEM GOVERNOR Full Pressure with Full Flow Filter 5 Regulation AIR CLEANER Dual Element Hydraulic ENGINE IDLER Automatic Idler Mechanical Fuel Pump Additional electric fuel lift pump on K2382 4 MUFFLER Low noise Muffler Top outlet can be rotated Made from long life aluminized steel Mechanical Governor ENGINE PROTECTION Shutdown on low oil pressure Output rating in watts is equivalent to volt amperes at unity factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced RANGER 225 GXT LINCOLN 5 2 INSTALLATION A 2 SAFETY PRECAUTIONS A 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 pre
27. al RANGER 225 GXT LINCOLN 5 6 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 Duty Cycle for the RANGER 225 GXT is 100 RANGER 225 GXT 225 Amps 25 Volts 210 Amps DC 25 Volts Constant Current Constant Voltage AUXILIARY POWER 200 Amps DC 20 Volts The RANGER 225 GXT can provide up to 9 000 watts of 120 240 volts AC single phase 60Hz power for continuous use and up to 10 500 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 one 50 amp 120 240 volt NEMA 14 50R receptacle and two 20 amp 120 volt NEMA 5 20R receptacles Output voltage is within 10 at all loads up to rated capacity All auxiliary power is protected by circuit breakers the 120V has 20 Amp circuit breakers for each duplex receptacle The 120 240V Single Phase has a 40 Amp 2 pole Circuit Breaker that disconnects both hot leads simultaneously CAUTION Do not connect any plugs that connect to the power receptacles in parallel Start the engine and set the IDLER control switch to the desired operating mode Set the CONTROL to 10 Voltage is now correct at the receptacles for auxil
28. and adjust the welding voltage with the output CONTROL at the welder NOTE The welding electrode is energized at all times unless an LN 25 with built in contactor is used If the output CONTROL is set below 3 the LN 25 contactor may not pull in CONNECTION OF THE LN 25 TO THE RANGER 225 GXT Shut the welder off Connect the electrode cable from the LN 25 to the ELECTRODE terminal of the welder Connect the work cable to the TO WORK termi nal of the welder Position the welder Polarity switch to the desired polarity either DC or DC CONNECTION OF K930 2 TIG MODULE TO THE RANGER 225 GXT The TIG Module is an accessory that provides high frequency and shielding gas control for AC and DC GTAW TIG welding See IM528 supplied with the TIG Module for installation instructions Note The TIG Module does not require the use of a high frequency bypass capacitor However if the RANGER 225 GXT is used with any other high fre quency equipment the bypass capacitor must be installed order kit T12246 INSTRUCTIONS ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the roof and case Sides in place as this provides maximum protection from moving parts and assures proper cooling air flow Read and understand all Safety Precautions before operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Owner s Manu
29. ations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations iv SAFETY iv PR CAUTIONS DE S RET 6 Eloigner les mat riaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut
30. cautions detailed engine starting operating and maintenance instructions and parts lists e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or 3 AR vent exhaust outside MOVING PARTS can injure Do not operate with doors open guards off amp Stop engine before servicing away from moving parts See additional warning information at front of this operator s manual MACHINE GROUNDING Because this portable engine driven welder or genera tor creates it s own power it is not necessary to con nect it s frame to an earth ground unless the machine is connected to premises wiring your home shop etc A WARNING 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 When this welder is mounted on a truck or trailer it s frame must be electrically bonded to the metal frame of the vehicle Use a 8 or larger copper wire connect ed between the machine grounding stud and the frame of the vehicle Where this engine driven welder is connected to premis
31. cuit Board PCB Open in miscellaneous leads Open lead in flashing or field circuit Faulty rotor Faulty Potentiometer R1 Faulty stator Field winding Faulty Field rectifier On PCB If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility Faulty P C Board Idler switch on High Idle Insufficient voltage present on idler solenoid terminals Voltage should be 12V to 14V DC External load on welder or auxiliary power Faulty wiring in solenoid circuit Faulty idler solenoid Faulty P C Board Poor work lead connection to work No voltage signal from the current sensor No open circuit voltage on output studs Faulty P C Board CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 225 GXT LINCOLN 5 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual Engine will not go to high idle when 1 No voltage signal from the using auxiliary power current sensor Auxiliary power load less than 100 to 150 watts Faulty P C Board Engine will not crank or is hard to Battery will not hold a charge crank Faulty Battery No or insufficient charging If all
32. d AC power gener ator It is built in a heavy gauge steel case for durabili ty on the job site WELDER CONTROLS FUNCTION AND OPERATION ENGINE SWITCH The engine switch is used to Start the Engine Select High Idle or Auto Idle while the engine is running and stop the Engine When placed in the OFF position the ignition circuit is de energized to shut down the engine When held in the START CH position the engine starter motor is energized When in HIGH IDLE amp position the engine will run continuously at high idle When in AUTO IDLE 19 position the engine will run continuously and the idler operates as follows Welding When the electrode touches the work the welding arc is initiated and the engine accelerates to full speed After welding ceases and no auxiliary power is being drawn the engine will return to low idle after approximately 10 to 14 seconds Auxiliary Power With the engine running at low idle and auxiliary power for lights or tools is drawn approximately 100 150 watts or greater from the receptacles 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 RANGER 225 GXT LINCOLN 5 2 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 we
33. dations Use the shortest length extension cord possible sized per the following table Current Voltage Load Amps Volts Watts 15 20 15 20 38 Maximum Allowable Cord Length in ft m for Conductor Size Conductor size is based on maximum 2 096 voltage drop RANGER 225 GXT LINCOLN 5 7 INSTALLATION TABLE A 7 ELECTRICAL DEVICE USE WITH THE RANGERO 225 GXT Type Common Electrical Devices Possible Concerns Resistive Heaters toasters incandescent light bulbs electric range hot pan skillet coffee maker NONE TV sets radios microwaves appliances with electrical control Voltage spikes or high voltage regulation can cause the capac itative elements to fail Surge protection transient protection and additional loading is recom mended for 100 fail safe operation DO NOT RUN THESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS Inductive Single phase induction motors drills well pumps grinders small refrigerators weed and hedge trimmers These devices require large current inrush for starting Some synchronous motors may be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures Capacitive Inductive Computers high resolution TV sets complicated electrical equipment An inductive type line condition er along with transient and surge protection is required and liab
34. de reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 b Use suitable clothing made from durable flame resistant 54 AUG 06 LINCOLN 5 material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal
35. e Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos KE FAKE Ke C l240 ei ggnestme rum e 123 d Jis kg Bae og Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo e BH HRUS fSI RBERELCT ORME ez HY Sol 2878 HSH due oua y cil jil READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos U
36. e from the LN 15 to the ELECTRODE terminal of the welder Connect the work cable to the TO WORK terminal of the welder Set the Polarity switch to the desired polarity either DC or DC Attach the single lead from the front of the LN 15 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current Set the RANGE switch to the WIRE FEED CV position Place the Engine switch in the Auto Idle position when welding with MIG wire instead of self shielded core wire weld starts can be improved by setting the idle mode to HIGH Adjust the wire feed speed at the LN 15 and adjust the welding voltage with the output CONTROL at the welder Output CONTROL must be set above 3 when welding with MIG wire instead of self shielded core wire weld starts can be improved by setting the idle mode to HIGH Note LN 15 Control Cable model will not work with the RANGER 225 GXT INSTALLATION A 5 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 current Place the engine switch in the AUTO IDLE posi tion When welding with MIG wire instead of self shielded core wire weld starts can be improved by setting the idle mode to HIGH Adjust wire feed speed at the LN 25
37. eplacement parts On Line Product Registration 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 For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page Installation Section A Technical Specifications Safety Precautions Machine Grounding Spark Welding Cable Connections Angle of Operation Lifting
38. es wiring such as that in your home or shop it s frame must be connected to the system earth ground See further connection instructions in the section enti tled Standby Power Connections as well as the arti cle on grounding in the latest National Electrical Code and the local code In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulat ed joints or to the metal framework of a building which has been effectively grounded The National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol is provided on the front of 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 properly maintained CAUTION An incorrect arrester may lead to damage to the engine or adversely affect performance TOWING The recommended trailer for use with this equipment for road in plant and yard towing by a vehicle is Lincoln s K2635 1 If the user adapts a non Linco
39. hat 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 If the battery is discharged and does not have enough power to start the engine see the battery charging instructions in the Battery section NOTE This machine is furnished with a wet charged battery if unused for several months the battery may require a booster charge Be careful to charge the bat tery with the correct polarity RANGER 225 GXT LINCOLN 5 4 WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the studs provided These connections should be checked periodically and tightened if neces sary 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 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 TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES 225 Amps 100 Duty Cycle 0 100 Ft 0 31m 100 150 Ft 31 46m 150 200 Ft 46 61m 1 0 AWG ANGLE OF OPERATION Internal combustion engines are designed to run in a level condition which is where the optimum perfor ma
40. he 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 the break in period approxi mately 50 running hours IN ORDER TO ACCOMPLISH THIS BREAK IN THE UNIT SHOULD BE SUBJECTED TO MODERATE LOADS WITHIN THE RATING OF THE MACHINE AVOID LONG IDLE RUNNING PERIODS REMOVE LOADS AND ALLOW ENGINE TO COOL BEFORE SHUTDOWN IMPORTANT The engine manufacturer s recommendation for the running time until the first oil change is as follows KOHLER CH23S 5 HRS The oil filter is to be changed at the second oil change Refer to the Engine Owner s Manual for more information RANGER 225 GXT LINCOLN 5 4 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 switch to the desired polarity The RANGE switch markings indicate the maximum current for that range as well as the typical electrode size for that range The OUTPUT Control provides fine adjust ment of the welding current within the select range For maximum output within a selected range set the OUTPUT Control at 10 For minimum output within selected range set the OUTPUT Control at 5 OU
41. icle manufacturer s instructions PRE OPERATION SERVICE CAUTION READ the engine operating and maintenance instructions supplied with this machine WARNING Stop engine while fueling Do not smoke when fueling e Keep sparks and flame away from tank Do not leave unattended while fueling Wipe up spilled fuel and allow GASOLINE fumes to clear before starting can cause fire engine or explosion po not overfill tank fuel expan sion may cause overflow GASOLINE FUEL ONLY INSTALLATION A 3 FUEL Fill the fuel tank with clean fresh lead free gasoline Observe fuel gauge while filling to prevent overfilling WARNING Damage to the fuel tank may cause fire or explosion Do not drill holes in the RANGERO 225 GXT base or weld to the RANGER 225 GXT base LUBRICATION SYSTEM CAPACITY INCLUDING FILTER Kohler 235 2 0 Quarts 1 9 Liters The RANGER 225 GXT is shipped with the engine crankcase filled with SAE 10W 30 oil Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required Make cer tain that the oil filler cap is tightened securely Refer to the engine Owner s Manual for specific oil recommen dations BATTERY CONNECTIONS CAUTION 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 t
42. ilities still exist DO NOT USE THESE DEVICES WITH A RANGERO 225 GXT The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect ed to the RANGER 225 GXT RANGER 225 GXT LINCOLN 5 8 INSTALLATION A 8 AUXILIARY POWER WHILE WELDING Simultaneous welding and power loads are permitted by following Table 1 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 SIMULTANEOUS WELDING POWER Output Selector Permissible Power Permissible Auxiliary Setting Watts Unity Power Current in Amperes Factor 120V or 240V Max Stick or Wire Feed Setting None 145 Stick Setting 3450 32 16 90 Stick Setting 6000 50 25 No Welding 9000 76 38 Each duplex receptacle is limited to 20 amps Not to exceed 40A per 120VAC branch circuit when splitting the 240 VAC output STANDBY POWER CONNECTIONS The RANGER 225 GXT is suitable for temporary standby or emergency power using the engine manu facturer s recommended maintenance schedule The RANGER 225 GXT can be permanently installed as a standby power unit for 240V 3 wire single phase 38 ampere service WARNING Connections must be made by a licensed electri cian who can determine how the 120 240V power can be adapted to the partic
43. ion or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct r
44. ith hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 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 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable
45. lding range Process STICK TIG constant current 8 range settings Range Setting Current Range 40 to 90 Amps 70 to 145 Amps 210DC 225AC MAX 120 to 210 DC 225 AC OPERATION POLARITY SWITCH Provides three selectable welding polarities AC amp DC CAUTION Never change the Polarity switch setting while welding This will damage the switch WIRE FEED constant voltage 1 range setting CAUTION Never change the RANGE Switch setting while welding This will damage the switch CONTROL DIAL 15 to 25V Up to 200 Amps Provides a fine welding current adjustment within the Range Switch settings in the STICK mode and weld ing voltage control with the Range switch set in the wire feed mode RANGER 225 GXT APPROXIMATE FUEL CONSUMPTION KOHLER 23 H P COMMAND CH23S 40 Gallons Hour 1 50 Liters Hour 7 Gallons Hour Low Idle No Load 2400 RPM High Idle No Load 3700 RPM AC CC Weld Output 225 Amps 25 Volts DC CC Weld Output 210 Amps 25 Volts DC CV Weld Output 200 Amps 20 Volts Auxiliary Power 9000 Watts 1 2 Gallons Hour 1 3 Gallons Hour 4 9 Liters Hour 1 2 Gallons Hour 4 5 Liters Hour 1 4 Gallons Hour 5 3 Liters Hour RANGER 225 GXT LINCOLN 5 B 3 STARTING SHUTDOWN INSTRUCTIONS STARTING THE ENGINE A WARNING EC Do not touch electrically live parts of electrode with skin or wet clothing IE Keep flammable material away
46. le or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Hecommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and folllow 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from 1 Batterymarch Park PO box 9101 Quincy 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 5 CYLINDER may explode if damaged 7 Use onl
47. ln trailer he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so there will be no undue stress to the framework RANGER 225 GXT LINCOLN 5 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 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 VEHICLE MOUNTING WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for compo nents such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Follow veh
48. nce is achieved The maximum angle of operation for the engine is 15 degrees from horizontal in any direction If the engine is to be operated at an angle provisions must be made for checking and maintain ing the oil at the normal FULL oil capacity in the crankcase in a level condition When operating at an angle the effective fuel capacity will be slightly less than the specified 12 Gal 45 L LIFTING The RANGER 225 GXT weighs approximately 685lbs 411kg with a full tank of gasoline A lift bail is mounted to the machine and should always be used when lifting the machine INSTALLATION ADDITIONAL SAFETY PRECAUTION A WARNING Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trail er or gas cylinder Do not lift machine if lift bail is FALLING EQUIPMENT can damaged cause injury Do not operate machine while suspended from lift bail HIGH ALTITUDE OPERATION At higher altitudes Welder output de rating may be necessary For maximum rating de rate the welder output 3 596 for every 1000 ft 305m above 3000 ft 914m If operation will consistently be at altitudes above 5 000 ft 1525m 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 n
49. nements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOU DER endi TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier LINCOLN 5 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou
50. ollow instructions printed on 1 When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed Failure to observe the proper polarity could result in damage to the charging circuit The positive battery cable has a red terminal cover If the battery requires charging from an external charger disconnect the negative battery cable first 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 N HARDWARE Both English and Metric fasteners are used in this welder ENGINE MAINTENANCE PARTS Air Filter Element Air Filter KOHLER C23S KOHLER 12 050 01 FRAM PH8172 KOHLER 47 083 03 FRAM CA79 KOHLER 24 083 02 Pre Cleaner w r KOHLER 24 050 10 CHAMPION RC12YC 030 GAP Oil capacity increases from 2 0 Qis to 2 1 015 when using this filter RANGER 225 GXT LINCOLN 5 E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A 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 precaution
51. ot give increased power Contact your local authorized engine service shop for high altitude jet kits that are available from the engine manufacturer CAUTION Do not operate with a high altitude jet installed at altitudes below 5000 ft This will result in the engine running too lean and result in higher engine operating temperatures which can shorten engine life MUFFLER OUTLET PIPE Using the clamp provided secure the outlet pipe to the tube with the pipe positioned such that it will direct the exhaust in the desired direction Tighten using a 9 16 socket or wrench RANGER 225 GXT LINCOLN 5 5 LOCATION VENTILATION The welder should be located to provide an unrestrict ed 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 225 GXT machines cannot be stacked CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off welder before making any electrical connections WIRE CONSTANT VOLTAGE CONNECTION OF LN 15 ACROSS THE ARC WIRE FEEDER The LN 15 has an internal contactor and the electrode is not energized until the gun trigger is closed When the gun trigger is closed the wire will begin to feed and the welding process is started Shut the welder off Connect the electrode cabl
52. recommended possible areas of current misadjustment have been checked and the problem persists Contact Loose battery cable your local Lincoln Authorized connection s Field Service Facility Engine shuts down Out of fuel Low oil level Engine does not develop full power 1 Fuel filter clogged Air filter clogged Engine is hard to start Spark plugs do not have specified gap Spark plugs are fouled Out of fuel Fuel filter clogged Electric fuel pump not working Electric pump equipped models only Mechanical fuel pump not work ing CAUTION 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 RANGER 225 GXT LINCOLN 5 TU ueu d nbe y e 10 eui M 2196911 5 su J sjeued y JO euo uo y 44 14 21919 Yad ST1O WAS TVOIH12313 LAN EN PER CAMIA NMOHS LNOYS 38 11 2 ALIAVO ALIHM LFIOIA A HO n 0000 ania AVHO MOVIE 8 ES ALIAVO LLZ o gH s H s gY DOT 3onvo and v ALIAVO Ovzz 7
53. s detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE 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 Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 225 GXT LINCOLN 5 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual 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 Cir
54. sed for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b 6j SAFETY WELDING and CUTTING gt 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 Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammab
55. should also be on your right side AR 2 4 4 Connect the work cable to the workpiece as close possible to the area being welded To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 2 d 5 Do not work next to welding power source Mar 95 LINCOLN 5 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is 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 In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electro
56. tilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch e Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o e exhaust o para remover fumo da zona respirat ria LEE 5H KE 9 emnmammm Zo VE VR TE FP Sf JR ER J SESTE 7 8 SENACESE 227H B 12452 7124174214 EE7IS Assia gal oe yay alal gt SA oa bis jua A Ae SE anal Ms ali e aac lt e Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas e Desligue a corrente antes de fazer servico e toque as partes el tricas nuas 7 3 4 354 amp V e na etio AAS Zelt AURI jud dell e Do not operate with panel open guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev
57. ular installation and comply with all applicable electrical codes The following information can be used as a guide by the electrician for most applications refer also to the connection diagram shown in Figure 1 Install a double pole double throw switch between the power company meter and the premises dis connect Switch rating must be the same or greater than the customer s premises disconnect and service over current protection Take necessary steps to assure load is limited to the capacity of the RANGER 225 GXT by installing a 40 amp 240V double pole circuit break er Maximum rated load for the 240V auxiliary is 38 amperes Loading above 38 amperes will reduce output voltage below the allowable 10 of rated voltage which may damage appliances or other motor driven equipment 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 Plug this cable into the 50 amp 120 240V recepta cle on the RANGER 225 GXT case front RANGER 225 GXT LINCOLN 5 9 INSTALLATION A 9 Figure 1 CONNECTION OF RANGER 225 GXT TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR 240 Volt POWER mE P d 60 Hz 3 Wire COMPANY Service NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVI
58. y compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and publication P I Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommend
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