Lincoln Electric IM829 User Manual
IM829-A
RETURN TO MAIN MENU
Ranger 250 LPG
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
May, 2005
11078, 11272
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
R
NRTL/C
OPERATOR’S MANUAL
Copyright © 2005 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
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
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN 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 & 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.
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
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.
____________________________________________________
1.c. 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 vaporizing on contact with 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.
____________________________________________________
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.
____________________________________________________
1.e. 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.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
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
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
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.
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 should also be on your right side.
___________________________________________________
1.g. 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.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii
SAFETY
ii
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.
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.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
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 Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. 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.
FUMES AND GASES
can be dangerous.
5.a.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.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.c. Shielding gases used 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.
5.d. 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.
5.e. Also see item 1.b.
vapors
Mar ‘95
to
iii
SAFETY
iii
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.
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. 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.
6.c. 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.
6.d. 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 flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
6.g. 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 circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only 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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” 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.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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 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. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
for selecting a QUALITY product by Lincoln Electric. We want you
Thank 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. 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___________________________________________________________________________
vv
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 replacement 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
“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:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
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.......................................................................................................A-1
Machine Specifications ........................................................................................................A-2
Safety Precautions. ..............................................................................................................A-3
Location and Ventilation................................................................................................A-3
Stacking ........................................................................................................................A-3
Angle of Operation ........................................................................................................A-3
Lifting.............................................................................................................................A-3
Additional Safety Precautions .......................................................................................A-3
High Altitude Operation.................................................................................................A-3
High Temperature Operation ........................................................................................A-3
Towing...........................................................................................................................A-3
Vehicle Mounting...........................................................................................................A-4
Pre-Operation Engine Service..............................................................................................A-4
Fuel ...............................................................................................................................A-4
Oil..................................................................................................................................A-5
Engine Coolant..............................................................................................................A-5
Battery Connections......................................................................................................A-5
Muffler Outlet Pipe ........................................................................................................A-5
Spark Arrester...............................................................................................................A-5
High Frequency Generators for TIG Applications .........................................................A-5
Remote Control.............................................................................................................A-5
Electrical Connections..........................................................................................................A-6
Machine Grounding.......................................................................................................A-6
Welding Terminals ........................................................................................................A-6
Welding Output Cables .................................................................................................A-6
Cable Installation...........................................................................................................A-6
Auxiliary Power Receptacles and Plugs...............................................................................A-7
Standby Power Connections................................................................................................A-7
Premises Wiring...................................................................................................................A-8
Connection of Lincoln Electric Wire Feeders .......................................................A-9 thru A-10
________________________________________________________________________________
vi
Operation.........................................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
General Description..............................................................................................................B-1
Design Features...................................................................................................................B-1
Engine Operation ..........................................................................................................B-1
Welding Controls..................................................................................................................B-2
Engine Controls....................................................................................................................B-3
Starting and Stopping the Engine .................................................................................B-3
Stopping .......................................................................................................................B-4
Welding Operation................................................................................................................B-4
Duty Cycle.....................................................................................................................B-4
DC Stick Welding ..........................................................................................................B-4
Constant Current (Stick) Welding..................................................................................B-4
Pipe Welding.................................................................................................................B-4
Fuel Consumption.........................................................................................................B-4
TIG Welding ..................................................................................................................B-5
Wire Welding-CV...........................................................................................................B-5
Typical Current Ranges for Tungsten Electrodes .........................................................B-5
Arc Gouging ..................................................................................................................B-6
Auxiliary Power .............................................................................................................B-6
Simultaneous Welding and Auxiliary Power Loads.......................................................B-6
Extension Cord Recommendations...............................................................................B-6
________________________________________________________________________________
Accessories.....................................................................................................Section C
Recommended Optional Equipment.....................................................................C-1
________________________________________________________________________
vii
TABLE OF CONTENTS
vii
Maintenance......................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance......................................................................................D-1
Engine Maintenance Components ........................................................................D-1
Engine Oil Change..........................................................................................D-2
Engine Oil Refill Capacities ............................................................................D-2
Oil Filter Change.............................................................................................D-2
Air Cleaner Service.........................................................................................D-2
Air Pre-Cleaner Service..................................................................................D-2
Air Filter Paper Element..................................................................................D-3
Spark Plug ......................................................................................................D-3
Spark Plug Service .........................................................................................D-3
Engine Adjustment..........................................................................................D-4
Battery Maintenance.......................................................................................D-4
Servicing Optional Spark Arrestor...................................................................D-4
Welder / Generator Maintenance ........................................................................D-5
Storage ...........................................................................................................D-5
Cleaning..........................................................................................................D-5
Brush Removal and Replacement..................................................................D-5
GFCI Receptacle Testing and Setting Procedure...........................................D-5
________________________________________________________________________
Troubleshooting..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Troubleshooting Guide..........................................................................................E-3
Troubleshooting Guide..........................................................................................E-4
Troubleshooting Guide ..........................................................................................E-5
________________________________________________________________________
Diagrams & Dimension Print..........................................................................Section F
________________________________________________________________________
Parts List ......................................................................................................P489 Series
________________________________________________________________________
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - RANGER 250 LPG ( K2336-1)
INPUT - LPG ENGINE
A-1
Make/Model Description Horsepower Operating
@ 3600 RPM SPEED Bore x Stroke
High
3700RPM
Full Load
3500RPM
Low Idle
2400RPM
K2336-1
Kohler CH20
OHV
2 Cylinder
4 Cycle
Air Cooled
LPG
Engine
20 HP
Displacement
3.03x 2.64 (77x67)
cu. in.(cu. cm)
38 (624)
in.(mm)
Starting Capacities
System
12VDC Battery
and starter
Push Button
Starter
Oil: 2.0Qts.(1.9L)
Group 58 Battery
(435 cold
crank amps)
RATED OUTPUT @ 104°F(40C°) - WELDER
Welding Output Volts at Rated Amps Duty Cycle Max. OCV @ 3700 RPM
CC STICK & PIPE DC Output 28 Volts at 250 Amps 100%
STICK / PIPE Output Range 40 to 250 Amps
TIG Output Range 20 to 250 Amps 60 Volts
CV WIREDC Output 28 Volts at 250 Amps 100%
CV WIREDC Output 27 Volts at 275 Amps 60%
CV WIRE Output Range 14 to 28 volts
RATED OUTPUT @ 104°F(40C°) - GENERATOR
Auxiliary Power
1
Fuel:
LPG
Cylinder
9,000 Watts Peak, 8000 Watts Continuous, 60 Hz
120/240 Volts
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
30.00** in. 21.50 in. 42.25 in.
762.0 mm 546.0 mm 1073.0 mm 482 lbs. (218kg.)
**Top of enclosure, add 6.0” (152mm) for exhaust.
ENGINE COMPONENTS
LUBRICATION VALVE LIFTERS FUEL SYSTEM GOVERNOR
Full Pressure Hydraulic- (Kohler) LPG regulator and Mechanical Governor
with Full Flow Filter vaporizer
AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION
Low noise Muffler: Top outlet Shutdown on low oil
Dual Element Automatic Idler can be rotated. Made from pressure.
long life, aluminized steel.
5% Regulation (Kohler)
1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to
rated capacity. When welding, available auxiliary power will be reduced.
RANGER 250 LPG
A-2
INSTALLATION
MACHINE SPECIFICATIONS - RANGER 250 LPG Engine (K2336-1)
RECEPTACLES AND CIRCUIT BREAKERS
RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS
A-2
(2) 120VAC GFCI Two 20AMP for Two Duplex Receptacle
Duplex (5-20R)
(1) 120/240VAC Dual Voltage One 40AMP for Dual Voltage (2-pole)
Full KVA (14-50R)
Below code 11272 two 40AMP Below code 11272 Battery
cicuit breakers were used for Charging Circuit Breaker was
Dual Voltage 25 amps.
20AMP for Battery Charging Circuit
15AMP for 42V Wire Feeder Power
RANGER 250 LPG
A-3
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.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
• See additional warning information at
front of this operator’s manual.
-----------------------------------------------------------
• Only qualified personnel should install,
use, or service this equipment.
LOCA TION AND VENTILA TION
The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to
avoid restricting the cooling air outlets. Also, locate
the welder so that the engine exhaust fumes are properly vented to an outside area.
STACKING
Ranger 250 LPG machines cannot be stacked.
ANGLE OF OPERATION
Engines are designed to run in the level condition
which is where the optimum performance is achieved.
The maximum angle of continuous operation is 15
degrees in any direction. If the engine is to be operated at an angle, provisions must be made for checking
and maintaining the oil level at the normal (FULL) oil
capacity in the crankcase.
LIFTING
The RANGER 250 LPG weighs approximately 482
lbs. (218Kg.). A lift bail is mounted to the machine and
should always be used when lifting the machine.
A-3
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 trailer
or gas cylinder.
FALLING • Do not lift machine if lift bail is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
------------------------------------------------------------------------
HIGH AL TITUDE OPERA TION
The Ranger 250 LPG requires no adjustment for high
altitude.
HIGH TEMPERATURE OPERATION
At temperatures above 40°C, output de-rating is necessary. For maximum output ratings, de-rate the
welder output 2Volts for every 10°C above 40°C.
TOWING
The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle
Lincoln’s K957-1. If the user adapts a non-Lincoln
trailer, the user 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.
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; roughness of surface on which the trailer will be operated; environmental conditions.
5. Conformance with federal, state and local laws.
(1) Consult applicable federal, state and local laws regarding spe-
cific requirements for use on public highways.
(1)
(1)
is
RANGER 250 LPG
A-4
VEHICLE MOUNTING
INSTALLATION
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 components such as suspension, axles and tires.
• Use appropriate nuts bolts and lockwashers to
attach the equipment base to the metal bed or
frame of vehicle.
• Follow vehicle manufacturer’s instructions.
------------------------------------------------------------------------
PRE-OPERATION SERVICE
CAUTION
READ the engine operating and maintenance
instructions supplied with this machine.
WARNING
fuel can cause fire or explosion.
LPG
-
• All leak testing must be done in a
well ventilated area free from all
potential ignition sources.
• Keep sparks and flame away from machine
and LPG supply cylinder.
• Do not expose the LPG supply cylinder to
temperatures exceeding 120°F (49°C).
• Do not weld on or near the LPG supply cylinder.
• Do not smoke or allow any potential ignition
sources near the LPG supply cylinder.
•
Always be certain that the LPG supply cylinder is
NOT in the welding circuit. Do not allow either
welding cable to come in contact with the supply
cylinder.
• Replace the fuel supply hose if there is
excessive abrasion, cracks or wear or if the
hose is cut.
------------------------------------------------------------------------
FUEL
A lift truck type coupler is provided on the supplied
fuel line for easy hand attachment to a lift truck type
LPG fuel cylinder. The fuel cylinder must meet D.O.T.
Specification 4E-240. The valve on the fuel cylinder
must
be installed on the outlet marked “LIQUID”.
The engine will not develop full power if connected to
the vapor outlet.
A-4
CAUTION
Be certain that the cylinder valve is CLOSED before
attempting to attach the fuel supply hose coupler to
the cylinder. Connect the coupler to the fuel cylinder
and tighten by hand.
___________________________________________
After connecting the fuel supply to the supply cylinder,
open the valve on the fuel cylinder and leak test by
brushing a 50/50 soap and water solution on to the following connections:
• Both ends of the fuel hose where it enters the metal connector.
• The threaded fitting on the end of fuel hose attached to the
Ranger 250 LPG fuel shut off solenoid.
• The fuel hose coupler and the connection to the cylinder valve.
• The stem of the cylinder valve and where the valve is attached
to the top of the cylinder.
• All other fittings on top of the fuel cylinder.
If growing bubbles appear, there is a leak. Re-tighten
connection or replace defective component. Retest to
make sure that there is no leak.
Leak test must be performed each time the fuel cylinder is replaced.
Always close the cylinder valve when the machine is
not being used.
The specification for aluminum lift truck cylinders are
shown below:
Capacity Cylinder Weight Foot ring
LP-Gas Volume Empty Outside
(LBS.) (Cu. In.) (LBS.) Diameter
33.5 2219 22.5 9 3/8”
43.5 2873 25.5 9 3/8”
Note: The Ranger 250 LPG cannot
draw LP gas cylinders such as those used for
recreation vehicles, trailers, grills, and boats.
be used with vapor
RANGER 250 LPG
A-5
INSTALLATION
A-5
OIL
The RANGER 250 LPG is shipped with the engine
crankcase filled with high quality 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. Check the oil level every four hours of running time during the first 25 running hours. Refer to
the engine Operator’s Manual for specific oil recommendations and break-in information. The oil change
interval is dependent on the quality of the oil and the
operating environment. Refer to the Engine Operator’s
Manual for the proper service and maintenance inter-
vals.
ENGINE COOLING SYSTEM
Air to cool the engine is drawn in lower set of louvers
on the case back. It is important that the intake air is
not restricted. Allow a minimum clearance of 2 feet
(0.6m) from the case back to a vertical surface.
BATTERY CONNECTION
CAUTION
Use caution as the electrolyte is a strong acid that
can burn skin and damage eyes.
------------------------------------------------------------------------
The RANGER 250 LPG is shipped with the negative
battery cable disconnected. Make certain that the
RUN-STOP switch is in the STOP position. Remove
the two screws from the rear battery tray using a
screwdriver or a 3/8" socket. Attach the negative battery cable to the negative battery terminal and tighten
using a 1/2" socket or wrench.
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 battery with the correct polarity.
------------------------------------------------------------------------
MUFFLER OUTLET PIPE
Using the clamp provided secure the outlet pipe to the
outlet tube with the pipe positioned such that it will
direct the exhaust in the desired direction. Tighten
using a 9/16" socket or wrench.
CAUTION
An incorrect spark arrester may lead to damage to
the engine or adversely affect performance.
------------------------------------------------------------------------
HIGH FREQUENCY GENERATORS FOR
TIG APPLICA TIONS
The K930-2 TIG Module is suitable for use with the
RANGER 250 LPG. The RANGER 250 LPG and any
high frequency generating equipment must be properly grounded. See the K930-2 Operating Manual for
completed instructions on installation, operation, and
maintenance.
REMOTE CONTROL
The RANGER 250 LPG is equipped with a 6 pin and a
14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control (optional) or
for TIG welding, the K870 foot Amptrol or the K963-3
hand Amptrol.
When in the CC-STICK, DOWNHILL PIPE, and CVWIRE modes or when a remote control is connected
to the 6-pin connector, the auto-sensing circuit in the
RANGER 250 LPG automatically switches the OUTPUT control from control at the welder to remote control .
The 14-pin connector is used to directly connect a
wire feeder or TIG Module (K930-2) control cable. In
the CV-WIRE mode, the RANGER 250 LPG autosensing circuit automatically makes the RANGER 250
LPG Output Control inactive and the remote voltage
control active when the control cable is connected to
the 14 pin connector.
When in the TOUCH START TIG mode and when a
Amptrol is connected to the 6 Pin connector the OUTPUT dial is used to set the maximum current range of
the CURRENT CONTROL of the Amptrol.
NOTE: When a wire feeder with a built in welding voltage control is connected to the 14 pin connector, do
not connect anything to the 6 pin connector.
SP ARK ARRESTER
Some federal, state or local laws may require that
gasoline or diesel 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, a suitable spark arrester, such as
the S24647 must be installed and properly maintained.
RANGER 250 LPG
A-6
INSTALLATION
A-6
ELECTRICAL CONNECTIONS
MACHINE GROUNDING
Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.)
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:
1) Be grounded to the frame of the welder using a
grounded type plug.
2) Be double insulated.
WARNING
Do not ground the machine to a pipe that carries
explosive or combustible material.
------------------------------------------------------------------------
When this welder is mounted on a truck or trailer, its
frame must be electrically bonded to the metal frame
of the vehicle. Use a #8 or larger copper wire connected between the machine grounding stud and the
frame of the vehicle. When this engine driven welder
is connected to premises wiring such as that in a
home or shop, its frame must be connected to the
system earth ground. See further connection instructions in the section entitled "Standby Power
Connections" as well as the article on grounding in the
latest U.S. 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 insulated joints, or to the metal framework of a building
which has been effectively grounded.
The U.S. 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.
WELDING TERMINALS
WELDING OUTPUT CABLES
With the engine off connect the electrode and work
cables to the output studs. The welding process dictates the polarity of the electrode cable. These connections should be checked periodically and tightened
with a 3/4" wrench.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
TABLE A-1
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Length
0-100Ft. (0-31meters)
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
Cable Size for
250 Amps
100% Duty Cycle
1 AWG (35mm2)
1 AWG (35mm
1/0 AWG (50mm
2
)
2
CABLE INSTALLATION
Install the welding cables to your RANGER 250 LPG
as follows.
1. The engine must be OFF to install welding cables.
2. Remove the flanged nuts from the output terminals.
3. Connect the electrode holder and work cables to
the weld output terminals. The terminals are identified on the case front.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding (the
“work”) is properly connected to the work clamp and
cable.
6. Check and tighten the connections periodically.
• Loose connections will cause the output terminals
to overheat. The terminals may eventually melt.
)
The RANGER 250 LPG is equipped with a toggle
switch for selecting "hot" welding terminals when in
the "WELD TERMINALS ON" position or "cold" welding terminals when in the "REMOTELY CONTROLLED" position.
RANGER 250 LPG
CAUTION
• Do not cross the welding cables at the output
terminal connection. Keep the cables isolated
and separate from one another.
------------------------------------------------------------------------
A-7
INSTALLATION
A-7
AUXILIARY POWER RECEPTACLES
Start the engine and set the “IDLER” control switch to
the “High Idle” mode. Voltage is now correct at the
receptacles for auxiliary power. This must be done
before a tripped GFCI receptacle can be reset properly. See the MAINTENANCE section for detailed information on testing and resetting the GFCI receptacle.
The auxiliary power of the RANGER 250 LPG consists of two 20 Amp-120 VAC (5-20R)GFCI duplex
receptacles and one 50 Amp 120/240 VAC (14-50R)
receptacle. The 240 VAC receptacle can be split for
single phase 120 VAC operation.
The auxiliary power capacity is 9,000 Watts Peak,
8000 Watts Continuous of 60 Hz, single phase power.
The auxiliary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The max
permissible current of the 240 VAC output is 33 Amps.
The 240 VAC output can be split to provide two separate 120 VAC outputs with a max permissible current
of 33 Amps per output to two separate 120 VAC
branch circuits (these circuits cannot be paralleled).
Output voltage is within ± 10% at all loads up to rated
capacity. All auxiliary power is protected by circuit
breakers.
2. Take necessary steps to assure load is limited to
the capacity of the RANGER 250 LPG by installing
a 40 amp, 240 VAC double pole circuit breaker.
Maximum rated load for each leg of the 240 VAC
auxiliary is 33 amperes.
Loading above the rated output will reduce output
voltage below the allowable - 10% of rated voltage
which may damage appliances or other motor-driven equipment and may result in overheating of the
RANGER 250 LPG engine and/or alternator windings.
3. Install a 50 amp, 120/240 VAC plug (NEMA Type
14-50) to the double-pole circuit breaker using No.
6, 4 conductor cable of the desired length. (The 50
amp, 120/240 VAC plug is available in the optional
K802R plug kit or as part number T12153-9.)
4. Plug this cable into the 50 Amp, 120/240 Volt
receptacle on the RANGER 250 LPG case front.
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 capacity of the associated
receptacle.
NOTE: The 240V receptacle has two 120V circuits,
but are of opposite polarities and cannot be paralleled.
STANDBY POWER CONNECTIONS
The RANGER 250 LPG is suitable for temporary,
standby or emergency power using the engine manufacturer’s recommended maintenance schedule.
The RANGER 250 LPG can be permanently installed
as a standby power unit for 240 VAC, 3 wire, single
phase, 33 amp service. Connections must be made
by a licensed electrician who can determine how the
120/240 VAC power can be adapted to the particular
installation and comply with all applicable electrical
codes.
1. Install the double-pole, double-throw switch
between the power company meter and the premises disconnect. Switch rating must be the same or
greater than the customer’s premises disconnect
and service over current protection.
RANGER 250 LPG
A-8
240 Volt
60 Hz.
3-Wire
Service
POWER
COMPANY
METER
240 VOLT
120 VOLT
120 VOLT
LOAD
N
NEUTRAL
BUS
GROUND
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GND
N
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
240 VOLT
GROUNDED CONDUCTOR
40AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
50 AMP, 120/240 VOLT
RECEPTACLE
INSTALLATION
CONNECTION OF RANGER 250 LPG TO PREMISES
A-8
WARNING
• Only a licensed, certified, trained electrician should install the machine to a premises or residential
electrical system. Be certain that:
•The installation complies with the National Electrical Code and all other applicable electrical codes.
•The premises is isolated and no feedback into the utility system can occur. Certain state and local
laws require the premises to be isolated before the generator is linked to the premises. Check your
state and local requirements.
•A double pole, double throw transfer switch in conjunction with the properly rated double throw cir
cuit breaker is connected between the generator power and the utility meter.
RANGER 250 LPG
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