Lincoln Electric IM931 User Manual

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IM931

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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.

September, 2006

11424

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

NRTL/C

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Page 2

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

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.

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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

Page 3

SAFETY

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.

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.

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.

5. b. 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 specific welding procedure and application 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.

5.c.

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.

vapors

3.j. Also see Items 6.c. and 8.

5.d. 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.e. 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.f. Also see item 1.b.

AUG 06

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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

Page 5

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. 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

Page 6

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___________________________________________________________________________

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.

Page 7

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

________________________________________________________________________________

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

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Accessories.....................................................................................................Section C

Recommended Optional Equipment.....................................................................C-1

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Page 8

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 .....................................................................................................P-489 Series

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Page 9

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - RANGER 250 LPG (K2336-2)

INPUT - LPG ENGINE

A-1

Make/Model Description Horsepower Operating

@ 3600 RPM SPEED Bore x Stroke

High

3700RPM

Full Load

3500RPM

Low Idle

2400RPM

Kohler

CH730S

OHV

2 Cylinder

4 Cycle

Air Cooled

LPG

Engine

25 HP

Displacement

3.27x 2.64 (83x67)

cu. in.(cu. cm)

44 (725)

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 WIRE DC Output 28 Volts at 250 Amps 100% CV WIRE DC Output 27 Volts at 275 Amps 60%

CV WIRE Output Range 14 to 28 volts

RATED OUTPUT @ 104°F(40C°) - GENERATOR

Auxiliary Power

Fuel:

LPG

Cylinder

10,500 Watts Peak, 9,500 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

Page 10

A-2

INSTALLATION

MACHINE SPECIFICATIONS - RANGER 250 LPG Engine (K2336-2)

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 50AMP for Dual Voltage (2-pole)

Full KVA (14-50R)

20AMP for Battery Charging Circuit

15AMP for 42V Wire Feeder Power

RANGER 250 LPG

Page 11

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.

LOCATION AND VENTILATION

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 ALTITUDE OPERATION

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)

RANGER 250 LPG

Page 12

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

Page 13

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 APPLICATIONS

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.

SPARK 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

Page 14

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

)

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.

------------------------------------------------------------------------

Page 15

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 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

Page 16

A-8

240 Volt

60 Hz. 3-Wire

Service

POWER

COMPANY

METER

240 VOLT

120 VOLT

LOAD

NEUTRAL BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

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

Page 17

A-9

INSTALLATION

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

Connection of LN-7 or LN-8 to the RANGER 250 LPG

1. Shut the welder off.

2. Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in Section F

A-9

e. Across-The-Arc Model:

Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"

Control Cable Model:

Set the "WELD TERMINALS" switch to "REMOTELY CONTROLLED"

f. Set the "WIRE FEEDER VOLTMETER" switch to

either "+" or "-" as required by the electrode polarity being used.

3. Set the "WIRE FEEDER VOLTMETER" switch to either "+" or "-" as required by the electrode being used.

4. Set the "MODE" switch to the "CV WIRE " position.

5. Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

6. Set the "WELD TERMINALS" switch to the "REMOTELY CONTROLLED" position.

7. Set the "IDLE" switch to the "HIGH" position.

Connection of LN-15 Wire Feeder to the RANGER 250 LPG

These connections instructions apply to both the LN15 Across-The-Arc and Control Cable models. 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.

g. Set the "ARC CONTROL" knob to "0" initially and

adjust to suit.

h. Set the "IDLE" switch to the "AUTO IDLE" position.

a. Shut the welder off.

b. For electrode Positive, connect the electrode cable

to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable "-" terminal of the welder and work cable to the "+" terminal of the welder.

c. Across-The-Arc Model:

Attach the single lead from the front of the LN15 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.

Control Cable Model:

Connect Control Cable between Engine Welder and Feeder.

d. Set the MODE switch to the "CV-WIRE " position.

RANGER 250

Page 18

A-10

Connection of the LN-25 to the RANGER 250 LPG

The LN-25 with or without an internal contactor may be used with the RANGER 250 LPG. See the appropriate connection diagram in Section F.

INSTALLATION

A-10

Connection of Prince Spool Gun 250 LPG

Connection of the Prince XL Spool Gun requires the use of the K1849-1 Adapter Module.

to the RANGER

Note: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the RANGER 250 LPG.

1. Shut the welder off.

2. For electrode Positive, connect the electrode cable from the LN-25 to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable from the LN-25 to the "-" terminal of the welder and work cable to the "+" terminal of the welder.

3. Attach the single lead from the front of the LN-25 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.

4. Set the MODE switch to the "CV-WIRE " position.

5. Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"

6. Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

1. Shut the Welder off.

2. For electrode Positive, connect the electrode cable to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable "-" terminal of the welder and work cable to the "+" terminal of the welder.

3. Connect the Control Cable of the Spool Gun to the Adapter Module and connect the Control Cable of the Adapter Module to the Welder.

4. Connect the Gas Hose.

5. Set the MODE switch to the "CV-WIRE " position.

6. Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"

7. Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

8. Set the "IDLE" switch to the "High" position.

7. Set the "IDLE" switch to the "AUTO" position. When not welding, the RANGER 250 LPG engine will be at the low idle speed. If you are using an LN-25 with an internal contactor, the electrode is not energized until the gun trigger is closed.

8. When the gun trigger is closed, the current sensing circuit will cause the RANGER 250 LPG engine to go to the high idle speed, the wire will begin to feed and the welding process started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

Connection of LN-742, K487-25 Spool Gun, and Cobramatic

1. Shut the welder off.

2. Connect per instructions on the appropriate connection diagram in Section F.

to the RANGER 250 LPG

RANGER 250 LPG

Page 19

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

Read and understand this entire section before operating your RANGER 250 LPG. Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists.

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such as output terminals or internal wiring.

•Insulate yourself from the work and ground.

•Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

•Use in open, well ventilated areas or vent exhaust outside

•Do not stack anything near the engine.

------------------------------------------------------------------------

MOVING PARTS can injure.

•Do not operate with doors open or guards off.

DESIGN FEATURES

ENGINE OPERATION

Before Starting the Engine:

1. Be sure the machine is on a level surface.

2. Open top engine door and remove the engine oil dipstick and wipe it with a clean cloth. Reinsert the dipstick and check the level on the dipstick.

3. Add oil (if necessary) to bring the level up to the full mark. Do not overfill. Close engine door.

4. See Engine Owner’s Manual for specific oil recommendations.

WARNING

• The combustion of LPG fuel does produce carbon monoxide. Although the level of CO

sion is lower than gasoline combustion, the exhaust from the Ranger 250 LPG can kill.

• Avoid breathing of vapor.

• Keep sparks and flame away from tank.

------------------------------------------------------------------------

emis-

•Stop engine before servicing.

•Keep away from moving parts

------------------------------------------------------------------------

• Only qualified personnel should operate this equipment.

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door closed and the side panels in place as these provide maximum protection from moving parts and insure proper cooling air flow.

GENERAL DESCRIPTION

The RANGER 250 LPG is an engine powered DC multi-process welding power source and 120 / 240 volt AC power generator. The engine drives a generator that supplies three phase power for the DC welding circuit and single phase power for the AC auxiliary outlets. The DC welding control system uses state of the art Chopper Technology (CT tm) for superior weld-

ing performance. The RANGER 250 LPG is not rec

ommended for pipe thawing.

RANGER 250 LPG

Page 20

B-2

OPERATION

B-2

WELDING CONTROLS:

1. OUTPUT CONTROL: The CONTROL dial pro-

vides continuous control of the welding current or welding voltage depending on the selected welding mode. This control is not active in the CC-STICK, DOWNHILL PIPE, and CV-WIRE modes when a remote control or wire feeder with remote control is connected to either the 6 pin or 14 pin Amphenol.

2. WELD MODE SELECTOR SWITCH:

(Provides four selectable welding modes)

CV-WIRE DOWNHILL PIPE CC-STICK TOUCH START TIG

3. ARC CONTROL:

The ARC CONTROL WIRE/STICK dial is active in the WIRE, STICK and DOWNHILL PIPE modes, and has different functions in these modes. This control is not active in the TIG mode.

CC-STICK mode: In this mode, the ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or crisp arc. Increasing the number from 10(soft) to +10(crisp) increases the short circuit current and prevents sticking of the electrode to the plate while welding. This can also increase spatter. It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with a setting at 0.

DOWNHILL PIPE MODE: In this mode, the ARC CONTROL dial sets the short circuit current (arc force) during stick welding to adjust for a soft or a more forceful digging arc (crisp). Increasing the number from -10(soft) to +10(crisp) increases the short circuit current which results in a more forceful digging arc. Typically a forceful digging arc is preferred for root and hot passes. A softer arc is preferred for fill and cap passes where weld puddle control and deposition (“stacking” of iron) are key to fast travel speeds. It is recommended that the ARC CONTROL be set initially at 0.

CV-WIRE mode: In this mode, turning the ARC CONTROL clockwise from –10 (soft) to +10 (crisp) changes the arc from soft and washed-in to crisp and narrow. It acts as an inductance control. The proper setting depends on the procedure and operator preference. Start with a setting at 0.

RANGER 250 LPG

Page 21

B-3

OPERATION

4. WELD OUTPUT TERMINALS WITH FLANGE NUT:

Provides a connection point for the electrode and work cables. Output Stud covers porvided on code 11272 and above.

5. GROUND STUD:

Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure.

6. 14-PIN CONNECTOR:

For attaching wire feeder control cables to the RANGER 250 LPG. Includes contactor closure circuit, auto-sensing remote control circuit, and 120V and 42V power. The remote control circuit operates the same as the 6-Pin connector.

7. 6-PIN CONNECTOR:

For attaching optional remote control equipment. When in the CC-STICK, PIPE, and CV-WIRE modes and when a remote control is connected to the Amphenol, the auto-sensing circuit in the RANGER 250 LPG automatically switches the OUTPUT control from control at the welder to remote control .

When using the TOUCH START TIG mode with a TIG Module connected to the RANGER 250 LPG, the OUTPUT control on the front of the RANGER 250 LPG is used to set the maximum current range of the CURRENT CONTROL on the TIG Module.

8. WELD TERMINALS CONTROL SWITCH:

In the WELD TERMINALS ON position, the output is electrically hot all the time. In the REMOTELY CONTROLLED position, the output is controlled by a wire feeder or amptrol device, and is electrically off until a

remote switch is depressed.

B-3

12. START PUSH BUTTON - Energizes the

starter motor to crank the engine.

13. IDLER SWITCH- Has two positions as follows:

1) In the HIGH position, the engine runs at the high idle speed controlled by the engine governor.

2) In the AUTO position, the idler operates as follows:

• When switched from HIGH to AUTO or after start-

ing the engine, the engine will operate at full speed for approximately 12 seconds and then go to low idle speed.

• When the electrode touches the work or power is

drawn for lights or tools (approximately 100 Watts minimum), the engine accelerates and operates at full speed.

• When welding ceases or the AC power load is

turned off, a fixed time delay of approximately 12 seconds starts. If the welding or AC power load is not restarted before the end of the time delay, the idler reduces the engine speed to low idle speed.

• The engine will automatically return to high idle

speed when there is welding load or AC power load reapplied.

14. ENGINE HOUR METER – Displays the total

time that the engine has been running. This meter is useful for scheduling prescribed maintenance.

STARTING AND STOPPING THE ENGINE

1. Remove all plugs connected to the AC power receptacles.

2. Set IDLER switch to AUTO.

3. Set the RUN/STOP switch to RUN.

4. Pull the choke to the full out position.

9. WIRE FEEDER VOLTMETER SWITCH:

Matches the polarity of the wire feeder voltmeter to the polarity of the electrode.

ENGINE CONTROLS:

10. RUN/STOP SWITCH - RUN position ener-

gizes the engine prior to starting. STOP position stops the engine. The oil pressure interlock switch prevents battery drain if the switch is left in the RUN position and the engine is not operating.

11. CHOKE - When pulled out, it closes the choke

valve on the engine carburetor for quick starting.

RANGER 250 LPG

5. Press and hold the engine START button until the engine starts.

6. Release the engine START button when the engine starts.

7. Push the choke back in.

8. The engine will run at high idle speed for approximately 12 seconds and then go to low idle speed. Allow the engine to warm up at low idle for several minutes before applying a load and/or switching to high idle. Allow a longer warm up time in cold weather.

Page 22

B-4

OPERATION

B-4

CAUTION

Operating the starter motor for more than 5 seconds can damage the motor. If the engine fails to start, release the switch and wait 10 seconds before operation the starter again. Do NOT push the START button while the engine is running because this can damage the ring gear and/or the starter motor.

STOPPING

Remove all welding and auxiliary power loads and allow the engine to run at low idle speed for a few minutes to cool the engine.

Stop the engine by placing the RUN-STOP in the STOP position.

Note: The engine will run for a breif moment (3 to 5

seconds) while the excess fuel is burned out of the system.

WELDER OPERATION

DUTY CYCLE

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.

DC Stick Welding

The RANGER 250 LPG can be used with a broad range of DC stick electrodes. The MODE switch provides two stick welding settings as follows:

Constant Current (CC-STICK) Welding

The CC-STICK position of the MODE switch is designed for horizontal and vertical-up welding with all types of electrodes, especially low hydrogen. The output CONTROL dial adjusts the full output range for stick welding.

The ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or crisp arc. Increasing the number from -10(soft) to +10(crisp) increases the short circuit current and prevents sticking of the electrode to the plate while welding. This can also increase spatter. It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with the dial set at

DOWNHILL PIPE Welding

This slope controlled setting is intended for "out-ofposition" and "down hill" pipe welding where the operator would like to control the current level by changing the arc length. The output CONTROL dial adjusts the full output range for pipe welding. The ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or more forceful digging arc (crisp). Increasing the number from

-10(soft) to +10(crisp) increases the short circuit current which results in a more forceful digging arc. Typically a forceful digging arc is preferred for root and hot passes. A softer arc is preferred for fill and cap passes where weld puddle control and deposition (“stacking” of iron) are key to fast travel speeds. This can also increase spatter. It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with the dial set at 0.

TYPICAL RANGER 250 LPG FUEL CONSUMPTION

Kohler CH20 S

20HP @ 3600 RPM

Lbs./Hr (Kg/hr)

Low Idle - No Load 2400 R.P.M. 3.42 (1.55)

High Idle - No Load 3700 R.P.M. 4.46 (2.02)

DC Weld Output 250 Amps @ 28 Volts 7.22 (3.27)

Auxiliary Power 8,000 Watts 7.23 (3.28)

RANGER 250 LPG

Page 23

B-5 TIG WELDING

The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the CONTROL dial is first set to the desired current and the tungsten is

OPERATION

• Set the "WELDING TERMINALS" switch to the "REMOTELY CONTROLLED" position. This will keep the "Solid State" contactor open and provide a "cold" electrode until the Amptrol or Arc Start Switch is pressed.

touched to the work. During the time the tungsten is touching the work there is very little voltage or current and, in general, no tungsten contamination. Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc.

When using the TIG Module, the OUTPUT control on the RANGER 250 LPG is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module.

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.

WIRE WELDING-CV

Connect a wire feeder to the RANGER 250 LPG according to

the instructions in INSTALLATION INSTRUCTIONS Section. The ARC CONTROL is not active in the TIG mode. To STOP a weld, simply pull the TIG torch away from the work. When the arc voltage reaches approximately 30 Volts the arc will go out and the machine will reset the current to the Touch Start level. To reinitiate the arc, retouch the tungsten to the work and lift. Alternatively, the weld can be stopped by releasing the Amptrol or arc start switch.

The RANGER 250 LPG in the CV-WIRE mode, permits it to be

used with a broad range of flux cored wire (Innershield and

Outershield) electrodes and solid wires for MIG welding (gas

metal arc welding). Welding can be finely tuned using the ARC

CONTROL. Turning the ARC CONTROL clockwise from –10

(soft) to +10 (crisp) changes the arc from soft and washed-in to

crisp and narrow. It acts as an inductance/pinch control. The

proper setting depends on the procedure and operator preferThe RANGER 250 LPG can be used in a wide variety of DC TIG

ence. Start with the dial set at 0. welding applications. In general the ‘Touch Start’ feature allows contamination free starting without the use of a Hi-frequency unit. If desired, the K930-2 TIG Module can be used with the RANGER 250 LPG. The settings are for reference.

Listed below are some wires suitable for use on this machine:

• Innershield - NR-311, NS-3M, NR-207, NR-203 Ni 1%, NR-212.

• Outershield - 0S-70, 0S-71M, 0S-71 ELITE.

RANGER 250 LPG settings when using the K930-2 TIG Module with an Amptrol or Arc Start Switch:

• Solid wires for MIG welding - .035 (0.9 mm), and

.045 (1.1 mm), L-50 and L-56, .035 (0.9 mm) and .045 (1.1 mm) Blue Max MIG 308 LS.

• Set the MODE Switch to the TOUCH START TIG setting.

Contact your local authorized Lincoln Electric Distributor or the

• Set the "IDLER" Switch to the "AUTO" position.

Lincoln Electric Company for specific wires used on certain applications with this machine.

TYPICAL CURRENT RANGES

Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH

Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)

1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel Tungsten Tungsten

.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6

0.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)

0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)

1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6

3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8 1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)

5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10 3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10) 1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)

(1)

FOR TUNGSTEN ELECTRODES

B-5

(2)

(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases. (2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):

Pure EWP

1% Thoriated EWTh-1

2% Thoriated EWTh-2

Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications. (3) DCEP is not commonly used in these sizes. (4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:

(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures

# 4 = 1/4 in. (6 mm) # 5 = 5/16 in. (8 mm) # 6 = 3/8 in. (10 mm) # 7 = 7/16 in. (11 mm) # 8 = _ in. (12.5 mm) #10 = 5/8 in. (16 mm)

and high duty cycles.

RANGER 250 LPG

Page 24

B-6

OPERATION

ARC GOUGING

The RANGER 250 LPG can be used for limited arc gouging. For optimal performance, set the MODE switch to CC-STICK and the ARC CONTROL to +10.

Set the CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table:

Electrode Diameter Current Range (DC, electrode positive)

1/8" (3.2mm) 30-60 Amps

B-6

5/32" (4.0mm) 90-150 Amps

3/16" (4.0mm) 200-250 Amps

AUXILIARY POWER:

Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings providing no welding current is being drawn.

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. If a GFCI receptacle is tripped, See the MAINTENANCE section for detailed information on testing and resetting the GFCI receptacle.

RANGER 250 LPG Simultaneous Welding and Power Loads

Welding

Output-Amps

0 100 150

200

250

* Each duplex receptacle is limited to 20 amps. ** Not to exceed 35 A per 120 VAC branch circuit when splitting the 240 VAC output.

Permissible Power-Watts

(Unity Power Factor)

8000 5300 4000 2700

750

The 120 V 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 240 V receptacle has two circuits, each of which measure 120 V to neutral but are of opposite polarities and cannot be paralleled.

Simultaneous Welding and Auxiliary Power Loads

The above auxiliary power ratings are with no welding load. Simultaneous welding and power loads are specified in the following table. The permissible currents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply (not both at the same time).

Permissible

Current in

@120 VAC *

66** 48** 38** 24

Auxiliary

-Amps

@ 240 VAC

33 24 19 12

Current

(Amps)

15 20 15 20 33

Voltage

Volts

120 120 240 240 240

RANGER 250 LPG Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

Load

(Watts)

1800 2400 3600 4800 8000

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

(9)

(18)

Conductor size is based on maximum 2.0% voltage drop.

Maximum Allowable Cord Length in ft. (m) for Conductor Size

40 30 75 60

(12)

(9) (23) (18)

50 150 100

(23) (15) (46) (30) (18)

125

88 225 175 100

(38) (27) (69) (53) (30)

175 138 350 275 175

RANGER 250 LPG

(53) (42)

(107)

(84) (53)

300 225 600 450 250

(91)

(69) (183) (137)

(76)

Page 25

C-1

ACCESSORIES

C-1

RECOMMENDED OPTIONAL EQUIPMENT

K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant

and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.). Order:

K957-1 Trailer K958-1 Ball Hitch K958-2 Lunette Eye Hitch K959-2 Fender & Light Kit K965-1 Cable Storage Rack

K1737-1 FOUR WHEEL ALL-TERRAIN UNDERCARRIAGE - For moving by hand at construction

sites. Heavy duty puncture resistant pneumatic tires.

K1770-1 UNDERCARRIAGE (FACTORY)

For moving by hand on a smooth surface. Heavy duty puncture resistant pneumatic tires and front caster. One or two gas cylinders can be mounted on the rear of the undercarriage with the installation of K1745-1 Cylinder Holder(s).

K802-N POWER PLUG KIT

Provides four 120 volt plugs rated at 20 amps each and one dual voltage, full KVA plug rated at 120/240 volts, 50 amps.

K802-R POWER PLUG KIT

Provides four 120 volt plugs rated at 15 amps each and one dual voltage, full KVA plug rated at 120/240 volts, 50 amps.

T12153-9 50 AMP, 120/240V POWER PLUG

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 6-50R receptacle, (which accepts 3-prong plugs.) For connection of Lincoln equipment with NEMA 6-50r plug.

TIG Welding

K1783-9 TIG Torch PTA-26V (25ft.) K963-3 Hand Amptrol K870 Foot Amptrol KP509 Magnum Parts Kit

K1739-1 CABLE CARRIER KIT - For use on K1737-1

and K1770-1 Undercarriages.

K1745-1 GAS CYLINDER HOLDER - Holds welding

gas cylinder or LPG Tank. (For products with LPG Tank). Can use either one or two holders with K17701 under carrage.

K2361-1 LPG TANK HOLDER KIT- Mounts to K1745-1

gas cylinder holder to secure LPG tank.

K886-2 CANVAS COVER - Protects machine when not

in use.

K1898-1 SPARK ARRESTER - Mounts inside

exhaust pipe.

K704 ACCESSORY KIT - 400 Amp Stick welding

Accessory Kit (Includes Headshield, electrode cable holder, work cable and work clamp.

K875 ACCESSORY KIT -Includes 20Ft. (6.1m) #6

electrode cable, 15Ft. (4.6) #6 work cable,Headsheild, FilterPlate,Work Clamp and Electrode Holder

Spool Gun

K1849-1 Adapter Module

K487-25 Magnum Spool Gun K488 Magnum Control Module

K691-10 Input Cable

K857 25 ft (7.5m) or K857-1 100 ft. (30.4m) REMOTE CONTROL - Portable control provides same dial range as

the output control on the welder. Has a convenient 6 pin plug for easy connection to the welder.

RANGER 250 LPG

Page 26

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

• Have qualified personnel do all maintenance and troubleshooting work.

• Turn the engine off before working inside the machine or servicing the engine.

• Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. If guards are missing from the machine, obtain replacements from a Lincoln Distributor. (See Operating Manual Parts List.)

Read the Safety Precautions in the front of this manual and in the Engine Owner’s Manual before working on this machine.

Keep all equipment safety guards, covers, and devices in position and in good repair. Keep hands, hair, clothing, and tools away from the gears, fans, and all other moving parts when starting, operating, or repairing the equipment.

------------------------------------------------------------------------

KOHLER ENGINE

FREQUENCY

Daily or Before

Starting Engine

5 Hours

Every 25 Hours

Every 100 Hours

Every 200 Hours

Every 1000 Hours

(1) Service more frequently when used in dusty areas and/or at high ambient

temperatures.

MAINTENANCE REQUIRED

• Check oil level.

• Check air cleaner for dirty, loose, or damaged parts.

• Check air intake and cooling areas, clean as necessary.

First Oil Change

• Service air pre-cleaner..

• Change engine oil.

• Clean or replace air filter element.

• Replace oil filter.

• Check spark plug and gap

• Check fuel lines and clamps.

(1)

Routine Maintenance

At the end of each day’s use, make certain that the valve on the LPG fuel supply cylinder is closed. Check the crankcase oil level and add oil if indicated.

ENGINE MAINTENANCE COMPONENTS

ITEM

Oil Filter Kohler 12 050 01, Fram PH8172

Air Filter Element Kohler 47 083 03, Fram CA79

Air Filter Pre-Cleaner Kohler 24 083 10

Spark Plug Champion RC12YC (.030" Gap)

Battery BCI Group 58 (435 CCA)

MAKE AND PART NUMBER

KOHLER CH730S ENGINE

RANGER 250 LPG

Page 27

D-2

MAINTENANCE

D-2

ENGINE OIL CHANGE

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 oil into a suitable container.

• 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:

•1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler

With oil filter replacement:

•2.0 US qt. (1.7 Imp qt., 1.9 liter)-Kohler

Use 4-stroke motor oil that meets or exceeds the requirements for API service classification SG or SH. Always check the API SERVICE label on the oil container to be sure it includes the letters SG or SH. SAE 10W-30 is recommended for general, all-temperature use, -5 F to 104 F (-20 C to 40 C).

6. Start the engine and check for oil filter leaks.

7. Stop the engine, and check the oil level. If necessary, add oil to the upper limit mark on the dipstick.

AIR CLEANER SERVICE

A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the engine in extremely dusty areas.

WARNING

• Never use gasoline or low flash point solvents

for cleaning the air cleaner element. A fire or explosion could result.

CAUTION

• Never run the engine without the air cleaner.

Rapid engine wear will result from contaminants, such as dust and dirt being drawn into the engine.

-----------------------------------------------------------------------

AIR PRE-CLEANER SERVICE

1. Loosen the cover retaining knob and remove the cover.

2. Remove the pre-cleaner from the paper element.

See Engine Owner’s Manual for more specific information 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 or recycling center for reclamation. Do not throw it in the trash, pour it on the ground or down a drain.

OIL FILTER CHANGE

1. Drain the engine oil.

2. Remove the oil filter, and drain the oil into a suitable container. Discard the used oil filter.

3. 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 by hand, until the gasket contacts the filter mounting base, then use an oil filter socket tool to tighten the filter an additional 1/2 to 7/8 turn.

3. Wash the pre-cleaner in warm water with detergent. Rinse the pre-cleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the pre-cleaner to air dry.

4. Saturate the pre-cleaner with new engine oil. Squeeze out all excess oil.

5. Reinstall the pre-cleaner over the paper element.

6. Reinstall the air cleaner cover. Secure cover with the cover retaining knob.

5. Refill the crankcase with the specified amount of the recommended oil. Reinstall the oil filler cap.

RANGER 250 LPG

Page 28

D-3

MAINTENANCE

D-3

AIR FILTER PAPER ELEMENT

1. Loosen the cover retaining knob and remove the cover.

2. Remove the pre-cleaner from the paper element.

3. Remove the element cover nut, element cover, and paper element.

4. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element with a new element. Handle new elements carefully; do not use if the sealing surfaces are bent or damaged.

5.When servicing the air cleaner, check the air cleaner

base. Make sure it is secured and not bent or damaged. Also check the element cover for damaged or improper fit. Replace all damaged air cleaner components.

NOTE: Before air cleaner is reassembled make sure rubber seal is in position around stud. Inspect, making sure it is not damaged and seals with the element cover.

6. Reinstall the paper element, pre-cleaner, element cover, element cover nut, and air cleaner cover. Secure cover with the cover retaining knob.

SPARK PLUG

To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.

5. Measure the plug gap with a feeler gauge. Correct as necessary by bending the side electrode.

6. Check that the spark plug washer is in good condition and thread the spark plug in by hand to prevent cross-threading.

7. After the spark plug is seated, tighten with a spark plug wrench to compress the washer. (See proper

spark plug torque which is specified below).

Spark Plug Gap: .030 in. (0.76 mm)-Kohler Engine

Spark Plug Torque:

20 ft. Lb. (27 N-m)-Kohler Engine

CAUTION

The spark plug must be securely tightened. An improperly tightened spark plug can become very hot and may cause engine damage. Use only the recommended spark plug or equivalent. A spark plug which has an improper heat range may cause engine damage.

------------------------------------------------------------------------

WARNING

NOTE: Before removing spark plug, the muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot.

------------------------------------------------------------------------

SPARK PLUG SERVICE

To ensure proper engine operation, the spark plug must be properly gapped and free of deposits.

1. Remove the spark plug cap.

2. Clean any dirt from around the spark plug base.

3. Use a plug wrench to remove the spark plug.

4. Visually inspect the spark plug. Discard them if the insulator is cracked or chipped. Clean the spark plug with a wire brush if it is to be reused.

RANGER 250 LPG

Page 29

D-4

MAINTENANCE

D-4

ENGINE ADJUSTMENT 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.

Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop.

BATTERY MAINTENANCE

To access the battery, Remove the 2 screws from the rear battery tray using a screwdriver or a 3/8" socket. Slide the battery tray out only far enough to access the battery terminals.

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 battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated.

CLEANING THE BATTERY

Keep the battery clean by wiping it with a damp cloth when dirty. If the terminals appear corroded, disconnect the battery cables and wash the terminals with an ammonia solution or a solution of 1/4 pound (0.12 kg) of baking soda and 1 quart (0.9461liter) of water. Be sure the battery vent plugs (if equipped) are tight so that none of the solution enters the cells.

After cleaning, flush the outside of the battery, the battery compartment, and surrounding areas with clear water. Coat the battery terminals lightly with petroleum jelly or a non-conductive grease to retard corrosion. Keep the battery clean and dry. Moisture accumulation on the battery can lead to more rapid discharge and early battery failure.

CHECKING THE ELECTROLYTE LEVEL

If battery cells are low, fill them to the neck of the filler hole with distilled water and recharge. If one cell is low, check for leaks.

CHARGING THE BATTERY

When you charge, jump, replace, or otherwise connect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The RANGER 250 LPG positive (+) battery terminal has a red terminal cover.

If you need to charge the battery with an external charger, disconnect the negative cable first, then the positive cable before you attach the charger leads. After the battery is charged, reconnect the positive battery cable first and the negative cable last. Failure to do so can result in damage to the internal charger components.

• USING A BOOSTER — connect positive lead to

battery first then connect negative lead to negative battery lead at engine foot.

BATTERY ACID can burn eyes and skin.

• Wear gloves and eye protection

and be careful when working near battery.

• Follow instructions printed on bat-

tery.

------------------------------------------------------------------------

RANGER 250 LPG

Follow the instructions of the battery charger manufacturer for proper charger settings and charging time.

SERVICING OPTIONAL SPARK ARRESTER

WARNING

Clean every 100 hours.

MUFFLER MAY BE HOT

• ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTER!

• DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER!

------------------------------------------------------------------------------------------

Page 30

D-5

MAINTENANCE

D-5

WELDER / GENERATOR MAINTENANCE

STORAGE: Store the RANGER 250 LPG in clean,

dry protected areas.

CLEANING: Blow out the generator and controls peri-

odically with low pressure air. Do this at least once a week in particularly dirty areas.

BRUSH REMOVAL AND REPLACEMENT: It’s nor-

mal for the brushes and slip rings to wear and darken slightly. Inspect the brushes when a generator overhaul is necessary.

CAUTION

• Do not attempt to polish slip rings while the engine is running.

WARNING

• Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions.

------------------------------------------------------------------------

GFCI RECEPTACLE TESTING AND RESETTING PROCEDURE

The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle:

• If the receptacle has tripped, first carefully remove any load and check it for damage.

• If the equipment has been shut down, it must be restarted.

• The equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equipment is providing at least 80 volts to the receptacle input terminals.

• The circuit breaker for this receptacle must not be tripped. Reset if necessary.

• Push the "Reset" button located on the GFCI receptacle. This will assure normal GFCI operation.

• Plug a night-light (with an "ON/OFF" switch) or other product (such as a lamp) into the GFCI receptacle and turn the product "ON".

• Push the "Test" button located on the GFCI receptacle. The night-light or other product should go "OFF".

• Push the "Reset" button, again. The light or other product should go "ON" again.

If the light or other product remains "ON" when the "Test" button is pushed, the GFCI is not working properly or has been incorrectly installed (miswired). If your GFCI is not working properly, contact a qualified, certified electrician who can assess the situation, rewire the GFCI if necessary or replace the device.

RANGER 250 LPG

Page 31

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

E-1

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 (SYMPTOMS)”. 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 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 250 LPG

Page 32

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-2

RECOMMENDED

COURSE OF ACTION

Major Physical or Electrical Damage is Evident.

Engine will not "crank".

Engine will "crank" but not start.

Engine shuts down shortly after starting.

1. I

f all recommended possible areas of misadjustment have been checked and the problem

persists,Contact your local

Lincoln Authorized Field Service Facility.

1. Battery is low.

2. Loose battery cable connections.

3. Faulty engine starter motor.

4. “Battery Circuit” circuit breaker is tripped.

1. LPG fuel cylinder empty.

2. Faulty fuel solenoid or faulty PC board or ignition system.

1. Low oil level.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

2. Faulty oil pressure switch or other engine component.

3. Open rotor circuit.

Battery does not stay charged.

1. Faulty battery.

2. Loose connections at battery or alternator.

3. Faulty engine alternator or charger module.

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 250 LPG

Page 33

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-3

RECOMMENDED

COURSE OF ACTION

Engine will not idle down to low speed.

Engine will not go to high idle when attempting to weld.

Engine will not go to high idle when using auxiliary power.

Engine does not develop full power.

1. Idler switch in High idle position.

2. External load on welder or auxiliary power.

3. Faulty PC board or idler solenoid.

1. Poor work lead connection to work.

2. "Contactor" switch is in wrong position.

3. Faulty PC board. Low idle speed set to low.

1. Auxiliary power load is less than 100 watts.

2. Faulty PC board.

1. Air filter clogged.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

2. Fouled spark plugs.

3. Valves out of adjustment.

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 250 LPG

Page 34

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-4

RECOMMENDED

COURSE OF ACTION

No welding power output.

Welder has output but no control.

Wire feeder does not work when control cable is connected to 14pin connector.

1. Poor work lead connection to work.

2. "Weld Terminals" switch in wrong position.

3. Faulty PC board or welder alternator.

1. Poor remote / control cable connection to 6-pin or 14-pin connector.

2. Faulty remote cable or faulty wire feeder or wire feeder cable.

3. Faulty control potentiometer or PC board.

1. Wire Feeder Power circuit breaker open.

2. Faulty control cable.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

3. Faulty wire feeder.

No auxiliary power.

1. Open circuit breakers.

2. Faulty connections to auxiliary receptacles.

3. GFCI tripped.

4. Faulty PC board or welder alternator.

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 250 LPG

Page 35

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-5

RECOMMENDED

COURSE OF ACTION

The welding arc is “cold.” The welding arc is not stable or is not satisfactory. the engine runs normally. The auxiliary power is normal.

1. Make sure the MODE selector switch is in the correct position for the process being used. (For example, CV-WIRE, PIPE, CCSTICK.)

2. Make sure the electrode (wire, gas, voltage, current etc.) is correct for the process being used.

3. Check for loose or faulty connections at the weld output terminals and welding cable connections.

4. The welding cables may be too long or coiled, causing an excessive voltage drop.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

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 250 LPG

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F-1

DIAGRAMS

F-1

RANGER 250 LPG

Page 37

F-2

DIAGRAMS

F-2

RANGER 250 LPG

Page 38

F-3

DIAGRAMS

F-3

RANGER 250 LPG

Page 39

F-4

DIAGRAMS

F-4

RANGER 250 LPG

Page 40

F-5

DIAGRAMS

F-5

RANGER 250 LPG

Page 41

F-6

or service this equipment.

Only qualified personnel should install,use

Keep away from moving parts.

Keep guards in place.

MOVING PARTS can injure

WARNING

Do not touch electrically live parts.

before servicing.

Disconnect NEGATIVE (-) Battery lead

Do not operate with panels open.

ELECTRIC SHOCK can kill

14 PIN

AMPHENOL

TO WORK

ENGINE WELDERS /LN-8 CONNECTION DIAGRAM

S24787-6

4-14-2000

TO LN-8 INPUT

CABLE PLUG

ELECTRODE CABLE

TO WIRE FEED UNIT

CAUTION:

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE AC WIRE FEEDER VOLTAGE, WHICH CAN DAMAGE THE CONTROL CIRCUIT. THE ENGINE GOVERNOR SETTING IS PRE-SET

AT THE FACTORY – DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPLICATIONS. SEE OPERATING MANUAL.

N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO

MATCH THE POLARITY OF THE ELECTRODE CABLE.

N.C. PLACE IDLER SWITCH IN “HIGH” POSITION.

K595 CONTROL CABLE

DIAGRAMS

F-6

RANGER 250 LPG

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F-7

DIAGRAMS

F-7

RANGER 250 LPG

Page 43

F-8

DIAGRAMS

F-8

RANGER 250 LPG

Page 44

F-9

DIAGRAMS

F-9

RANGER 250 LPG

Page 45

F-10

DIAGRAMS

F-10

RANGER 250 LPG

Page 46

F-11

DIAGRAMS

F-11

RANGER 250 LPG

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 number.

Page 47

M19410

CIRCUIT

BREAKERS

41.20

17.50 19.50

TRUCK/UNDERCARRIAGE MOUNTING HOLES

7.22

24.86

2.62

5.57

30.65

NOTE: CASE FRONT GRAPHICS MAY NOT MATCH ALL CODES.

42.10

20.80

10.28 10.78

29.88

33.62

36.24

23.50

15.50

F-12

DIMENSION PRINT

F-12

RANGER 250 LPG

Page 48

NOTES

RANGER 250 LPG

Page 49

NOTES

RANGER 250 LPG

Page 50

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch 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 mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

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 HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Page 51

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

Page 52

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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Lincoln Electric IM931 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual