Lincoln Electric 225 GXT manual

RANGER 225 G XT OPERA TOR’S MANUAL For Machines with Code Number 11522 IM969 December, 2008 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 T[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS 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 Z87. I standards. 4. b. Use suitable clothing made from durable flame-resistant material to protect your ski[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8 . b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical [...]

Mar. ʻ93 iv SAFETY iv 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 LʼArc 1. Protegez-vous contre la secousse électrique: a. Les c[...]

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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

vi vi T ABLE OF CONTENTS Page Installation ................................................................................................................... .... Section A Technical Specifications ....................................................................................................... A-1 Safety Precautions ........................[...]

A-1 INST ALLA TION RANGER® 225 GXT A-1 TECHNICAL SPECIFICA TIONS - RANGER® 225 GXT ( K2733-1) INPUT - GASOLINE ENGINE RA TED OUTPUT @ 104°F (40°C)- WELDER RA TED OUTPUT @ 104°F (40°C)- GENERA TOR Welding Output AC Constant Current 225A / 25V / 100% DC Constant Current 210A / 25V / 100% DC Constant Voltage 200A / 20V / 100% Auxiliary Power 1 9[...]

A-2 INST ALLA TION RANGER® 225 GXT A-2 SAFETY PRECAUTIONS MACHINE GROUNDING Because this portable engine driven welder or genera- tor creates itʼs own power, it is not necessary to con- nect itʼs frame to an earth ground, unless the machine is connected to premises wiring (your home, shop, etc.). To prevent dangerous electric shock, other equip-[...]

FUEL Fill the fuel tank with clean, fresh, lead-free gasoline. Observe fuel gauge while filling to prevent overfilling. OIL 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 [...]

A-4 INST ALLA TION RANGER® 225 GXT A-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 s[...]

A-5 INST ALLA TION RANGER® 225 GXT A-5 LOCA TION / VENTILA TION 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 outs[...]

A-6 INST ALLA TION RANGER® 225 GXT 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 [...]

A-7 INST ALLA TION RANGER® 225 GXT A-7 TABLE lll ELECTRICAL DEVICE USE WITH THE RANGER® 225 GXT. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker. Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage appliances with electri[...]

A-8 INST ALLA TION RANGER® 225 GXT A-8 STANDBY POWER CONNECTIONS The RANGER® 225 GXT is suitable for temporary, standby, or emergency power using the engine manu- facturerʼs 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. (Connections mus[...]

A-9 INST ALLA TION RANGER® 225 GXT A-9 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. Figure 1 CONNECTION OF RANGER® 225 GXT TO PREMISES WIRING W ARNING[...]

WELDER CONTROLS - FUNCTION AND OPERA TION 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” position, the engine starter motor is[...]

“ 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. Never change the “RANGE” Switch setting while welding. This will damage the switch. ------------------------------------------------------------------------ “ CONTROL” DIAL Pro[...]

B-3 OPERA TION B-3 ST ARTING/SHUTDOWN INSTRUCTIONS STARTING THE ENGINE Be sure all Pre-Operation Maintenance has been per- formed. Also, read the Engine Ownerʼs Manual before starting for the first time. Remove all loads connected to the AC power recepta- cles. Use the choke control as follows: KOHLER ENGINE - Always pull the choke control out whe[...]

B-4 OPERA TION B-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[...]

B-5 OPERA TION B-5 * 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 SUMMARY OF WELDING PROCESSES CONTROL ELECTRODE CABLE IDLE WHEN NOT TO START PROCESS USED MODE WELDING WELDING STICK No AUTO Hot Touch electrode to work. Welding starts immediately [...]

C-1 ACCESSORIES C-1 RANGER® 225 GXT 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 e[...]

C-2 ACCESSORIES C-2 RANGER® 225 GXT RECOMMENDED EQUIPMENT STICK K704 Accessory Kit- (400 AMP Capacity) which includes: • Electrode Holder & Cable • Work Clamp & Cable • Headshield K875 Accessory Kit- (150 AMP Capacity) WIRE FEED K449 LN-25 - Includes internal contactor for across the arc operation (no control cable). Provides “cold[...]

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 [...]

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 Ownerʼs Manual for [...]

D-3 MAINTENANCE D-3 ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS 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. ---[...]

E-1 TROUBLESHOOTING E-1 RANGER® 225 GXT 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. CAUTION This Troubleshooting Guide is provided to help you locate and repair[...]

E-2 TROUBLESHOOTING E-2 RANGER® 225 GXT Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLE[...]

E-3 TROUBLESHOOTING E-3 RANGER® 225 GXT Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLE[...]

F-1 DIAGRAMS F-1 RANGER® 225 GXT NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code nu[...]

F-2 DIAGRAMS F-2 RANGER® 225 GXT M202 66 C RANGER 225 GXT, RANGER 10 ,00 0, RANGER 3 PHASE, W ELD MARK 2 25, ZR8 LN- 25 OR L N-1 5 ACROSS THE ARC CONNECTION DI AGRAM TO WORK ELECTRO DE TO W ORK TO WO R K ELE CTROD E CABL E WORK C LI P L EAD N.A. WELDING CABL E MUST BE SIZED FOR CURR ENT AND DUTY CY CLE OF APPLICATION. N.B. USE POLARITY S WITCH TO [...]

F-3 DIMENSION PRINT F-3 RANGER® 225 GXT M2181 3 A.02 CIR CU CU IT BR E AKE AKE RS 41.20 17.50 19.50 14.13 TRUCK/ UNDERCARRIAGE MOUNTI NG HOLES 24.86 2.6 7.2 2 29.88 CENTER OF GRAVITY WITH OIL IN ENGINE AND EM PTY FUEL TANK. 21.44 20.80 42.10 33.62 36.24 10.27 10.78 NOTE: CASEFRONT GRAPHICS MAY NOT MATCH ALL CODES .[...]

NOTES RANGER® 225 GXT[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA EL [...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

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