Lincoln Electric RANGER 250 User Manual

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Ranger 250
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.
April, 2003
10795; 10854; 10953; 10954
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
Copyright © 2003 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
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i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause can­cer, birth defects, and other reproductive harm.
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
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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.
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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.
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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.
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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.
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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
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SAFETY
ii
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical (earth) ground.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES can be dangerous.
5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
3.f.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.
3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.b.
Do not weld in locations near chlorinated hydrocarbon coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors form phosgene, a highly toxic gas, and other irritating prod­ucts.
5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
vapors
Mar ‘95
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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
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SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv­antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.
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.
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.
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.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR 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___________________________________________________________________________
vv
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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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
Pre-Operation Engine Service..............................................................................................A-4
Oil..................................................................................................................................A-4
Fuel ...............................................................................................................................A-4
Engine Coolant..............................................................................................................A-4
Battery Connections......................................................................................................A-4
Muffler Outlet Pipe ........................................................................................................A-4
Spark Arrester ...............................................................................................................A-4
High Frequency Generators for Tig Applications ..........................................................A-4
Remote Control .............................................................................................................A-4
Electrical Connections..........................................................................................................A-5
Machine Grounding.......................................................................................................A-5
Welding Terminals ........................................................................................................A-5
Welding Output Cables .................................................................................................A-5
Cable Installation...........................................................................................................A-5
Auxiliary Power Receptacles and Plugs...............................................................................A-6
Standby Power Connections ................................................................................................A-6
Premises Wiring ...................................................................................................................A-7
Connection of Lincoln Electric Wire Feeders .......................................................................A-8
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vi
Operation.........................................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
General Description..............................................................................................................B-1
Design Features ...................................................................................................................B-1
Engine Operation ..........................................................................................................B-1
Fuel ...............................................................................................................................B-1
Welding Controls ..................................................................................................................B-2
Engine Controls....................................................................................................................B-3
Starting and Stopping the Engine .................................................................................B-3
Stopping .......................................................................................................................B-4
Welding Operation................................................................................................................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
Typical Current Ranges for Tungsten Electrodes .........................................................B-5
Wire Welding-CV...........................................................................................................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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TABLE OF CONTENTS
vii
Maintenance......................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance ......................................................................................D-1
Kohler / Onan Engine Maintenance Components .................................................D-1
Kohler Engine .......................................................................................................D-1
Onan P220 OHV Engine .......................................................................................D-1
Engine Oil Change..........................................................................................D-2
Engine Oil Refill Capacities (Kohler / Onan) ...................................................D-2
Oil Filter Change .............................................................................................D-2
Air Cleaner Service .........................................................................................D-2
Air Pre-Cleaner Service ...........................................................................D-2,D-3
Air Filter Paper Element..................................................................................D-3
Spark Plug ......................................................................................................D-3
Spark Plug Service .........................................................................................D-3
Fuel Filter ........................................................................................................D-4
Engine Adjustment ..........................................................................................D-4
Battery Maintenance .......................................................................................D-4
Option Spark Arrestor...............................................................................D-4,D-5
Welder / Generator Maintenance ........................................................................D-5
Storage ...........................................................................................................D-5
Cleaning..........................................................................................................D-5
Brush Removal and Replacement ..................................................................D-5
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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
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Diagrams & Dimension Print..........................................................................Section F
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Parts List ......................................................................................................P411 Series
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Page 9
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - Ranger 250 ( K1725-2, K1725-4)
INPUT - GASOLINE ENGINE
A-1
Make/Model Description Horsepower Operating
@ 3600 RPM SPEED Bore x Stroke
K1725-2
Kohler CH20
OHV
K1725-4
Onan P220
OHV
2 Cylinder
4 Cycle
Air Cooled
Gasoline
Engine
20 HP
20.5 HP
High
3700RPM
Full Load
3500RPM
Low Idle
2400RPM
Displacement
3.03x 2.64 (77x67)
3.15x 2.56 (80x65)
cu. in.(cu. cm)
38 (624)
39.9 (653)
in.(mm)
Starting Capacities
System
12VDC Battery
and starter
Push Button
Starter
Group 58 Battery
(435 cold
crank amps)
Fuel: Oil: 2.0qts.(1.9L)
Fuel: Oil: 1.6qts.(1.6L)
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 80 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
1
12gal.
12gal.
(45.4L)
(45.4L)
9,000 Watts Peak, 8500 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 500 lbs. (227kg.)
**Top of enclosure, add 6.0” (152mm) for exhaust.
ENGINE COMPONENTS
LUBRICATION VALVE LIFTERS FUEL SYSTEM GOVERNOR
Full Pressure Solid-(Onan P220 OHV) Diaphragm Pulse Pump(Onan OHV) Mechanical Governor
with Full Flow Filter Hydraulic- (Kohler) Mechanical Fuel Pump (Kohler)
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)
Centrifugal Flywheel (Onan OHV)
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
Page 10
A-2
INSTALLATION
MACHINE SPECIFICATIONS - Ranger 250 (K1725-2, K1725-4)
RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS
A-2
(2) 120VAC Duplex (5-20R) Two 20AMP for Two Duplex Receptacle (1) 120/240VAC Dual Voltage Two 40AMP for Dual Voltage
Full KVA (14-50R)
25AMP for Battery Charging Circuit 15AMP for 42V Wire Feeder Power
RANGER 250
Page 11
A-3
INSTALLATION
A-3
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.
------------------------------------------------------------------------
LIFTING
The RANGER 250 weighs approximately 575 lbs. with a full tank of gasoline. A lift bail is mounted to the machine and should always be used when lifting the machine.
ADDITIONAL SAFETY PRECAUTIONS
WARNING
FALLING EQUIPMENT can cause injury.
• Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder.
• Lift only with equipment of ade­quate lifting capacity.
Be sure machine is stable when lifting.
------------------------------------------------------------------------
HIGH ALTITUDE OPERATION
At higher altitudes, output de-rating may be neces­sary. For maximum rating, de-rate the welder output
3.5% for every 1000 ft. (305m). Contact an autho­rized engine service shop for modifications to operate above 5,000 ft. (1525m).
• 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 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. When operating the welder at an angle, the effective fuel capacity will be slightly less than the specified 12 gallons.
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, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue stress to the framework.
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.
(1)
is
RANGER 250
Page 12
A-4
5. Conformance with federal, state and local laws.
(1) Consult applicable federal, state and local laws
regarding specific requirements for use on public highways.
INSTALLATION
(1)
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instruc­tions supplied with this machine.
WARNING
• Stop engine and allow to cool before fueling
• Do not smoke when fueling
• Fill fuel tank at a moderate rate and do not overfill
• Wipe up spilled fuel and allow fumes to clear before starting engine
• Keep sparks and flame away from tank
-------------------------------------------------------------------------------
OIL
The RANGER 250 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 inter­vals.
A-4
BATTERY CONNECTION
CAUTION
Use caution as the electrolyte is a strong acid that can burn skin and damage eyes.
------------------------------------------------------------------------
The RANGER 250 is shipped with the negative bat­tery cable disconnected. Make certain that the RUN­STOP 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.
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.
FUEL
USE GASOLINE FUEL ONLY
WARNING
Fill the fuel tank with clean, fresh fuel. The capaci­ty of the fuel tank is 12 gallons (45.4 liters). When the fuel gauge reads empty the tank contains approximately 2 gallons (45.4 liters).of reserve fuel.
NOTE: The fuel tank is mounted below the engine
so a fuel shutoff valve is not required.
-----------------------------------------------------------------------
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.
RANGER 250
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. The Ranger 250 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 is equipped with a 6 pin and a 14 pin Amphenol 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 K812 hand Amptrol.
Page 13
A-5
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 automatically switches the OUTPUT control from con­trol at the welder to remote control .
INSTALLATION
A-5
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.
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 auto-sensing cir­cuit automatically makes the Ranger 250 Output Control inactive and the wire feeder voltage control active when the control cable is connected to the 14 pin connector.
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.
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.
WELDING TERMINALS
The Ranger 250 is equipped with a toggle switch for selecting "hot" welding terminal when in the "WELD TERMINALS ON" position or "cold" welding terminal when in the "REMOTELY CONTROLLED" position.
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.
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Length
0-100Ft. (0-31meters)
100-150 Ft. (30-46 meters)
Cable Size for
250 Amps
100% Duty Cycle
1 AWG
1 AWG
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 securely connected to the metal 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.
RANGER 250
150-200 Ft. (46-61 meters)
TABLE A-1
1/0 AWG
CABLE INSTALLATION
Install the welding cables to your RANGER 250 as fol­lows.
1. The gasoline 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.
Page 14
A-6
INSTALLATION
A-6
6. Check and tighten the connections periodically.
• Loose connections will cause the output terminals to overheat. The terminals may eventually melt.
CAUTION
• Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another.
------------------------------------------------------------------------
AUXILIARY POWER RECEPTACLES
The auxiliary power of the RANGER 250 consists of two 20 Amp-120 VAC (5-20R) duplex receptacles and one 50 Amp 120/240 VAC (14-50R) receptacle. The 240 VAC receptacle can be split for single phase 120 VAC operation.
The auxiliary power capacity is 9,000 Watts Peak, 8500 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 35 Amps. The 240 VAC output can be split to provide two sepa­rate 120 VAC outputs with a max permissible current of 35 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.
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.
2. Take necessary steps to assure load is limited to the capacity of the RANGER 250 by installing a 40 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 35 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 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 case front.
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 120 V circuits, but are of opposite polarities and cannot be paralleled.
STANDBY POWER CONNECTIONS
The RANGER 250 is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended maintenance schedule.
The RANGER 250 can be permanently installed as a standby power unit for 240 VAC, 3 wire, single phase, 35 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.
RANGER 250
Page 15
A-7
240 Volt
60 Hz.
3-Wire
Service
INSTALLATION
CONNECTION OF RANGER 250 TO PREMISES WIRING
240 VOLT
POWER
COMPANY
METER
DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.
120 VOLT
120 VOLT
40AMP
240 VOLT
GROUNDED CONDUCTOR
NEUTRAL BUS
GROUND
A-7
N
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
LOAD
DOUBLE
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
240 VOLT
50 AMP, 120/240 VOLT
RECEPTACLE
POLE
CIRCUIT
BREAKER
GND
N
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
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
Page 16
A-8
INSTALLATION
A-8
CONNECTION OF LINCOLN ELEC­TRIC WIRE FEEDERS
Connection of LN-7 or LN-8 to the Ranger 250
1. Shut the welder off.
2. Connect the LN-7 or LN-8 per instructions on the
appropriate connection diagram in Section F
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 " posi-
tion.
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 the LN-25 to the Ranger 250
The LN-25 with or without an external contactor may be used with the Ranger 250. See the appropriate connection diagram in Section F.
Note: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the Ranger 250.
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.
Connection of an LN-23P Wire Feeder to the Ranger 250
1. Shut the welder off.
2. Connect the LN-23P as per instructions on the appropriate connection diagram in Section F. (NOTE): When connecting an LN-23P to the Ranger 250, a K350-1 adapter kit must be used.
3. Set the "VOLTMETER" switch to "-".
4. Set the "MODE" switch to "CV WIRE" position.
5. Set the "WELD TERMINALS" switch to "REMOTELY CONTROLLED".
6. Set the "ARC CONTROL" knob to "0" initially and adjust to suit.
7. Set the "IDLE" switch to the "AUTO" position. When not welding, the Ranger 250 engine will be at the low idle speed. If you are using an LN-23P with the K350-1 adapter kit, the electrode is not energized until the gun trigger is closed. When the gun trigger is closed, the current sensing cir­cuit will cause the Ranger 250 engine to go to the high idle speed, the wire will begin to feed and the welding process can be started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.
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.
7. Set the "IDLE" switch to the "AUTO" position. When not welding, the Ranger 250 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 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, Spool Gun, and Cobramatic to Ranger 250
1. Shut the welder off.
2. Connect per instructions on the appropriate con­nection diagram in Section F.
RANGER 250
Page 17
B-1
OPERATION
B-1
SAFETY PRECAUTIONS
Read and understand this entire section before operating your Ranger 250. 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.
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.
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.
ADD FUEL
WARNING
GASOLINE can cause fire or explosion.
Stop engine when fueling.
Do not smoke when fueling.
Do not overfill tank.
Avoid contact with skin or
breathing of vapor.
Keep sparks and flame away from tank.
------------------------------------------------------------------------
1. Remove the fuel tank cap.
2. Fill the tank approximately 4 inches (100mm) from the top of the filler neck to allow for fuel expansion (observe the fuel gauge while filling). DO NOT FILL THE TANK TO THE POINT OF OVERFLOW.
3. Replace the fuel cap and tighten securely.
4. See Engine Owner’s Manual for specific fuel rec­ommendations.
GENERAL DESCRIPTION
The Ranger 250 is a gasoline 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 is not recom
mended for pipe thawing.
RANGER 250
-
Page 18
B-2
OPERATION
B-2
1
15
14
2
13
12
11
10
3
9
8
4
WELDING CONTROLS:
1. OUTPUT CONTROL: The CONTROL dial
provides continuous control of the welding current or welding voltage depending on the selected welding mode. This control is not active in the CC-STICK, 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 PIPE CC-STICK TOUCH START TIG
7
6
5
CC-STICK/PIPE modes: In these modes, the ARC CONTROL knob sets the short circuit current during stick welding (arc-force). Increasing the number from ­10 to +10 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.
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.
3. ARC CONTROL:
The ARC CONTROL WIRE/STICK dial is active in the WIRE, STICK and PIPE modes, and has different functions in these modes. This control is not active in the TIG mode. DC PIPE mode for machines below code 10900.
RANGER 250
4. WELD OUTPUT TERMINALS WITH FLANGE NUT:
Provides a connection point for the electrode and work cables.
Page 19
B-3
OPERATION
5. GROUND STUD: (graphic)
Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure.
6. 14-PIN AMPHENOL:
For attaching wire feeder control cables to the Ranger
250. 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 Amphenol.
7. 6-PIN AMPHENOL:
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 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, the OUTPUT control on the front of the Ranger 250 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.
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.
B-3
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 ALTERNATOR TROUBLE
LIGHT-The engine alternator light is off when battery
charging system is functioning normally. If light turns on, the alternator or the voltage regulator may not be operating correctly. The light may also come on due to the battery not holding a charge. It is normal for the light to come on during shut down of the engine. The light will remain lit with the meters for a short period of time after the engine has shut down.
15. 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.
5. Press and hold the engine START button until the engine starts.
11. CHOKE - When pulled out, it closes the choke
valve on the engine carburetor for quick starting.
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.
RANGER 250
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 20
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.
NOTE: When starting a Ranger 250 for the first time, or after an extended period of time of not operating, it will take longer than normal because the fuel pump has to fill the fuel line and carburetor.
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: A fuel shut off valve is not required on the Ranger 250 because the fuel tank is mounted below the engine.
WELDER OPERATION
DC Stick Welding
The Ranger 250 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 knob sets the short circuit cur­rent during stick welding (arc-force). Increasing the number from -10 to +10 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 0.
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 knob sets the short circuit current during stick welding (arc-force). Increasing the number from -10 to +10 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 0.
TYPICAL RANGER 250 FUEL CONSUMPTION
Kohler CH20 Onan P220 OHV Running Time for
20HP @ 3600 RPM 20.5HP @ 3600 RPM 12 gallons-hours Gal./Hr (Liters/Hr) Gal./Hr (Liters/Hr) CH20/P220 OHV
Low Idle - No Load 2400 R.P.M. 0.6 (2.3) 0.5 (1.9) 20/24
High Idle - No Load 3700 R.P.M. 0.8 (3.0) 0.8 (3.0) 15/15
DC Weld Output 250 Amps @ 28 Volts 1.40 (5.3) 1.6 (5.9) 8.6/7.5
Auxiliary Power 8,500 Watts 1.47 (5.6) 1.7 (6.4) 8.2/7.0
RANGER 250
Page 21
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
OPERATION
When using the TIG Module, the OUTPUT control on the Ranger 250 is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module.
the tungsten is 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.
WIRE WELDING-CV
Connect a wire feeder to the Ranger 250 according to the instructions in INSTALLATION INSTRUCTIONS Section. The Ranger 250 in the CV-WIRE mode, permits it to
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.
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 control. The proper setting depends on the pro­cedure and operator preference. Start with the dial set
The Ranger 250 can be used in a wide variety of DC TIG
at 0.
welding applications. In general the ‘Touch Start’ feature allows contamination free starting without the use of a Hi­frequency unit. If desired, the K930-2 TIG Module can be used with the Ranger 250. 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-204-H.
Ranger 250 settings when using the K930-2 TIG Module with an Amptrol or Arc Start Switch:
• Set the MODE Switch to the TOUCH START TIG setting.
• Set the "IDLER" Switch to the "AUTO" position.
• Outershield - 0S-70, 0S-71M.
• 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 "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
Contact your local authorized Lincoln Electric Distributor or the Lincoln Electric Company for specific wires used on certain applications with this machine.
pressed.
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
Page 22
B-6
OPERATION
B-6
ARC GOUGING
The Ranger 250 can be used for limited arc gouging. For optimal performance, set the MODE switch to CC­STICK 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
5/32" (4.0mm) 90-150 Amps
3/16" (4.0mm) 150-200 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 consists of two 20 Amp-120 VAC (5-20R) duplex receptacles and one 50 Amp 120/240 VAC (14-50R) receptacle. The 240 VAC receptacle can be split for single phase 120 VAC operation.
The auxiliary power capacity is 9,000 Watts Peak, 8500 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 35 Amps.
The 240 VAC output can be split to provide two sepa­rate 120 VAC outputs with a max permissible current of 35 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.
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).
Current
(Amps)
15 20 15 20 35
Ranger 250 Simultaneous Welding and Power Loads
Welding
Output-Amps
Permissible Power-Watts
(Unity Power Factor)
Permissible
Current in
Auxiliary
-Amps
@120 VAC *
0 100 150
200
250
8500 6200 4800 3400 2000
70** 52** 40** 28 16
* Each duplex receptacle is limited to 20 amps. ** Not to exceed 35 A per 120 VAC branch circuit when splitting the 240 VAC output.
Ranger 250 Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Voltage
Volts
120 120 240 240 240
Load
(Watts)
1800 2400 3600 4800 8500
14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
30
60
(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)
75
50 150 100
60
(23) (15) (46) (30) (18)
125
88 225 175 100
(38) (27) (69) (53) (30)
175 138 350 275 175
@ 240 VAC
35 26 20 14
8
(53) (42)
(107)
(84) (53)
300 225 600 450 250
(91)
(69) (183) (137)
(76)
RANGER 250
Page 23
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).
K1739-1 CABLE CARRIER KIT - For use on K1737-1
and K1770-1 Undercarriages.
K1745-1 SINGLE GAS CYLINDER HOLDER - For
use on K1770-1 Undercarriage. One or two may be installed on an undercarriage.
K1788-1 ROLL CAGE - Gives added damage protection.
K886-2 CANVAS COVER - Protects machine when not
in use.
K1690-1 GFCI RECEPTACLE KIT - Includes one UL
approved 120V ground fault circuit interrupter duplex type receptacle with cover and installation instruc­tions. Replaces the factory installed 120V duplex
receptacle. Each receptacle of the GFCI Duplex is rated at 20 Amps, the maximum total current from the
GFCI Duplex is limited to the 20 Amps. Two kits are required.
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.)
TIG Welding K1783-9 TIG Torch PTA-26V (25ft.) K963-2 Hand Amptrol K870 Foot Amptrol S19257-2 Power Cable Adapter KP506 Magnum Hook-Up Kit KP509 Magnum Parts Kit
Spool Gun K1692-2 Prince XL Spool Gun (25ft.)
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.
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
Page 24
D-1
MAINTENANCE
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 Owners 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.
Routine Maintenance
At the end of each day’s use, refill the fuel tank to minimize moisture condensation in the tank. Running out of fuel tends to draw dirt into the fuel system. Also, check the crankcase oil level and add oil if indicated.
D-1
KOHLER ENGINE
FREQUENCY
Daily or Before
Starting Engine
5 Hours
Every 25 Hours
Every 100 Hours Every 100 Hours Every 100 Hours
Every 100 Hours Every 200 Hours Every 200 Hours
(1) Service more frequently when used in dusty areas and/or at high ambient
temperatures.
MAINTENANCE REQUIRED
• Fill fuel tank.
• 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.
• Replace fuel filter element.
• Clean or replace air filter element.
• Spark Arrester
• Replace oil filter.
• Check spark plug and gap
• Check fuel lines and clamps.
(1)
(1)
(1)
ONAN P220 OHV
FREQUENCY
Daily or Before
Starting Engine
After initial 20 Hours
Every 50 Hours
Every 100 Hours
Every 200 Hours
Every 500 Hours
Every 1000 Hours
(1) Service more frequently when used in dusty areas and/or at high ambient
temperatures.
MAINTENANCE REQUIRED
• Fill fuel tank.
• Check oil level.
Check air cleaner for dirty, loose, or damaged parts.
• Check air intake and cooling areas, clean as necessary.
• Inspect for loose hardware and retighten.
Check for fuel leakage from fuel system. Repair if needed.
•Change oil and oil filter.
• Clean spark plugs.
• Clean outer element of air cleaner.
• Change engine oil.
• Clean fuel strainer.
• Replace air cleaner assembly.
• Inspect, clean, and re-gap Spark Plugs.
• Change engine oil filter.
• Clean Carburetor.
• Clean cylinder head.
• Adjust engine valve clearance.
• Replace spark plugs.
• Replace fuel lines and filter.
(1)
(1)
(1)
ENGINE MAINTENANCE COMPONENTS
ITEM
ONAN P220 OHV ENGINE KOHLER CH20 ENGINE
Oil Filter Onan 122-0737, Fram PH4967 Kohler 1205001, Fram PH3614
Air Filter Element Onan 187-6068 Kohler 4708303, Fram CA79
Air Filter Pre-Cleaner N/A Kohler 2408302
Fuel Filter Onan 187-6119 Kohler 2405002, Fram G
Spark Plug Onan 167-1638, NGK BPR4EY Champion RC12YC (.030" Gap)
Battery BCI Group 58 (435 CCA) BCI Group 58 (435 CCA)
MAKE AND PART NUMBER
RANGER 250
Page 25
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
•1.5 US qt. (1.2 Imp qt., 1.4 liter)-Onan P220 OHV
With oil filter replacement:
•2.0 US qt. (1.7 Imp qt., 1.9 liter)-Kohler
•1.65 US qt. (1.4 Imp qt., 1.6 liter)-Onan P220 OHV
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). For the Onan engine, it is recommended that SAE 30 oil be used above 82 F (27 C). 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.
5. Refill the crankcase with the specified amount of the recommended oil. Reinstall the oil filler cap.
6. Start the engine and check for oil filter leaks.
7. Stop the engine, and check the oil level. If 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.
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.
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.
RANGER 250
5. Reinstall the pre-cleaner over the paper element.
6. Reinstall the air cleaner cover. Secure cover with the cover retaining knob.
Page 26
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
.025 in. (0.64 mm)-Onan Engine’s
Spark Plug Torque:
20 ft. Lb. (27 N-m)-Kohler Engine
11 ft. Lb. (14 N-m)-Onan Engine’s
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
Page 27
D-4
MAINTENANCE
D-4
FUEL FILTER
1. Check the fuel filter for water accumulation or sedi­ment.
2. Replace the fuel filter if it is found with excessive water accumulation or sediment.
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.
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 battery.
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 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. Follow the instructions of the battery charger manu­facturer for proper charger settings and charging time.
SERVICING OPTIONAL SPARK ARRESTER
Clean every 100 hours.
MUFFLER MAY BE HOT
WARNING
ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTER!
DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER!
------------------------------------------------------------------------------------------
RANGER 250
Page 28
D-5
MAINTENANCE
WELDER / GENERATOR MAINTENANCE
STORAGE: Store the RANGER 250 in clean, dry pro-
tected 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.
D-5
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.
------------------------------------------------------------------------
RANGER 250
Page 29
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
Page 30
E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
POSSIBLE AREAS OF
MISADJUSTMENT(S)
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. Out of fuel.
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. Engine alternator trouble light is on while machine is running.
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
Page 31
E-3
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
POSSIBLE AREAS OF
MISADJUSTMENT(S)
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. Fuel 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. Air filter clogged.
3. Fouled spark plugs.
4. 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
Page 32
E-4
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
POSSIBLE AREAS OF
MISADJUSTMENT (S)
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 14 pin Amphenol.
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 Amphenol 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 (if installed).
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
Page 33
E-5
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
TROUBLESHOOTING
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
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
Page 34
F-1
DIAGRAMS
F-1
RANGER 250
Page 35
F-2
DIAGRAMS
F-2
RANGER 250
Page 36
F-3
DIAGRAMS
F-3
RANGER 250
Page 37
F-4
DIAGRAMS
F-4
RANGER 250
Page 38
F-5
DIAGRAMS
F-5
RANGER 250
Page 39
F-6
Keep away from moving parts.
Keep guards in place.
MOVING PARTS can injure
DIAGRAMS
F-6
4-14-2000
S24787-6
TO WORK
or service this equipment.
Only qualified personnel should install,use
ENGINE WELDERS /LN-8 CONNECTION DIAGRAM
WARNING
Do not operate with panels open.
Disconnect NEGATIVE (-) Battery lead
ELECTRIC SHOCK can kill
before servicing.
Do not touch electrically live parts.
CABLE PLUG
TO LN-8 INPUT
14 PIN
AMPHENOL
K595 CONTROL CABLE
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.
RANGER 250
Page 40
F-7
DIAGRAMS
F-7
RANGER 250
Page 41
F-8
DIAGRAMS
F-8
RANGER 250
Page 42
F-9
DIAGRAMS
F-9
RANGER 250
Page 43
F-10
DIAGRAMS
F-10
RANGER 250
Page 44
F-11
DIAGRAMS
F-11
RANGER 250
Page 45
F-12
DIAGRAMS
F-12
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..
RANGER 250
Page 46
F-13
DIAGRAMS
Output &
Arc Cont.
Mode
P6-J6
Shunt
2 1
206S
204S
L3
Select
P7 - J7
218
220
222
16
8
277
279
278
P2 - J2
214
12
9
1
6
75
77
76
Key
210C
215
228
P1 - J1
Amphenol,
Model
Select,
Engine &
Battery
Function
7
1
5K
200N
229
211
224B
225
Hot Start
16
8
2
4
210B
76A
75A
77A
Sense/
Idler/
PWM
P3-J3
16
9
Key
1
14
9
1
8
13
261
260
251
23
25
252
208B
PCB2 WELD CONTROL PC BOARD
L2
A.03
F-13
G4284
75
10K
76
77
CCW
OUTPUT CONT. POT
R1
279
10K
278
ARC CONTROL
CCW
277
R2
(LOCATED BELOW
TERMINAL 2)
A
1
4
2
3
CV
TIG
CC
PIPE
220
222
214
218
S6 MODE SELECTOR SWITCH
W3
STATOR
WELD
WINDINGS
W1
D1 - THREE PHASE BRIDGE RECTIFIER
W10
W5
Twisted
Pair
W4
W6
B1
C11
RANGER 250G - WIRING DIAGRAM FOR CODE 10954 (KOHLER) 10953 (ONAN P220 OHV)
301
B2
R4
C10
HEATSINK
B3
302
W9
TWISTED PAIR
261
260
W10
W2
W3
W6
W11
23
25
W5
B7
B8
B4
C8
14
B5
PCB 1
300 AMP
MODULE
C9
13
B6
W8
3
6
WRAP TWO TURNS #3 &
#6 LEADS IN DIRECTION
SHOWN THROUGH
TOROID
6
3
L1 CHOKE
206A
206B
204S
SHUNT
50MV=400 AMPS
206S
208B
42 VAC
FIELD WINDING
6
3
STATOR AUX. WINDING
208A
206C
206A
208C
206B
S5
POLARITY
VOLTMETER
208
W7
WIRE FEED POWER
WINDING
5J
+
HOUR METER
224B
224
5G
5K
215 210C
200N
R3
200B
9
3
5H
5K
9
7
5
GND-E
GND-E
GND-K
GND-N
BOTTOM GND INSIDE CASEFRONT
SHOWN IN
POSITIVE (+)
POSITION
21
SWITCH
41
42 VAC
42
5
TOP GND. SCREW ON
INSIDE OF CASE FRONT
5N
41A
CB8
15A
42A
206C
BYPASS
IDLER CONTROL
5C
5N
FILTER
252
251
S4
SHOWN IN
"AUTO" POSITION
212
800uf
221
200
200A
150vdc
201
5H
201A
6
20A
32
BLACK
WHITE
J102
GND-G
GND-C
GND-D
GND-G
GND-B
31
GND-N
GND. SCREW ON LEFT
INSIDE CASEFRONT
31
42A
41A
32
K
I
J
A
42VAC
115VAC
IDLE
SOLENOID
C3
D3
7
5G
5B
5A
FRAME GND.
208C
ASSEMBLY
211A
229
209
211A
221
BLACK
6
6B
CB6
BLACK
WHITE
6F
5C
115/230V
WHITE
TERM.
2A
76A
75A
77B
76B
75B
ABCDE
REMOTE
CONTACTOR
CONTROL
228
Battery Charge
Light PL2
ENGINE
BLOCK
GND-H
BATTERY
12 VOLT
+
STARTER
U
J51
P51
R
4
225
3
R
2
212A
1
V
WHITE
ENGINE TERMINAL
BLOCK
224
STOPS THE ENGINE
GROUNDING THIS CIRCUIT
GND-K
GND. SCREW ON
FAN BAFFLE.
4
4A
S3
CONTACTOR
CONTROL
4A
4B
2B
GND-B
F
AMPHENOL 2
GROUND
1
-
STARTER
CR1
REGULATOR
OIL
210
GND-J
SHOWN IN
SOLENOID
B-
AC
B
+
AC
IGNITION
SWITCH
PRESSURE
2
2A
"WELDING ON"
POSITION
2
GND-J
FRAME
GROUND
FUEL
SHUTOFF
SOLENOID
FLYWHEEL ALTERNATOR
MODULE
ENGINE COMPONENTS
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)
L2, L3: RF CHOKES
8
16
1
9
6
12
ELECTRICAL SYMBOLS PER E1537
1
7
CONNECTORS VIEWED FROM INSERTION END
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
211
210B
S2
START
BUTTON
210A
210A210
S1
CB1
SWITCH
(SHOWN IN
15A
POSITIVE BRUSH CONNECTED
SILVER
GND-D
77B
EFG
5J
RUN POS.)
CB7
ROTOR
TO SLIP RING NEAREST
TO THE LAMINATION
5C
3A
6B
3
BLACK
3
6B
3A
CB2
20A
50A
50A
CB5
3E
6E
BLACK
WHITE
5B
5A
BLACK
J101
J100
SILVER
3E
GND-C
GND-B
77A
2B
4B
75B
76B
GND-A
D
CHB
AMPHENOL 1
REMOTE
GROUND
CONTACTOR
CONTROL
S1RUN-STOP
3A
3D
GND-A
FRAME GND.
21
WORK
RANGER 250
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
CENTER OF GRAVITY WITH OIL IN
ENGINE AND EMPTY FUEL TANK
TRUCK/UNDERCARRIAGE MOUNTING HOLES
41.20
17.50 19.50
42.10
20.80
"A"
"B"
29.88
33.62
36.24
10.28 10.78
7.22
24.86
2.6
F-14
DIAGRAMS
23.50
15.50
KOHLER CH20
22.25
15.25
ONAN P220OHV
F-14
8/00
M19410
DIMENSION PRINT RANGER 250
DIMENSION “A”
DIMENSION “B”
RANGER 250
Page 48
NOTES
RANGER 250
Page 49
NOTES
RANGER 250
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
World's Leader in Welding and Cutting Products
Sales and Service through Subsidiaries and Distributors Worldwide
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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