Lincoln Electric RANGER 250 User Manual

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Ranger 250

IM741-A

April, 2003

For use with machines having Code Numbers: 10795; 10854; 10953; 10954

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.

OPERATOR’S MANUAL

Copyright © 2003 Lincoln Global Inc.

World's Leader in Welding and Cutting Products •

Sales and Service through Subsidiaries and Distributors Worldwide •

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

Lincoln Electric RANGER 250 User Manual

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

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

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.

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes

outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame welding arc or when the engine is running.

Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

____________________________________________________

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

____________________________________________________

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

___________________________________________________

1.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.

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.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii

 

SAFETY

 

ii

 

 

 

 

 

 

 

 

 

ELECTRIC SHOCK can

kill.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

Semiautomatic DC Constant Voltage (Wire) Welder.

DC Manual (Stick) Welder.

AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

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.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES can be dangerous.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating 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.

Mar ‘95

iii

SAFETY

iii

WELDING SPARKS can

cause fire or explosion.

6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot

materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

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 though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places.

Always wear safety glasses with side shields when in a welding area.

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.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

Away from areas where they may be struck or subjected to physical damage.

A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Mar ‘95

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

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

Sûreté Pour Soudage A L’Arc

1.Protegez-vous contre la secousse électrique:

a.Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b.Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c.Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le refroidir.

e.Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f.Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

2.Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

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 ray-

onnement 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

zones où l’on pique le laitier.

6.Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7.Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8.S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9.Assurer une ventilation suffisante dans la zone de soudage.

Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10.Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11.Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR 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

v

Thank You

v

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then “Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

vi

vi

TABLE OF CONTENTS

 

Page

Installation.......................................................................................................................

Section A

Technical Specifications.......................................................................................................

A-1

Machine Specifications ........................................................................................................

A-2

Safety Precautions. ..............................................................................................................

A-3

Location and Ventilation................................................................................................

A-3

Stacking ........................................................................................................................

A-3

Angle of Operation ........................................................................................................

A-3

Lifting.............................................................................................................................

A-3

Additional Safety Precautions .......................................................................................

A-3

High Altitude Operation .................................................................................................

A-3

High Temperature Operation ........................................................................................

A-3

Towing...........................................................................................................................

A-3

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

________________________________________________________________________________

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

________________________________________________________________________________

Accessories .....................................................................................................

Section C

Recommended Optional Equipment.....................................................................

C-1

________________________________________________________________________

vii

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

 

________________________________________________________________________

 

Troubleshooting ..............................................................................................

Section E

 

How to Use Troubleshooting Guide.......................................................................

E-1

 

Troubleshooting Guide ..........................................................................................

E-2

 

Troubleshooting Guide ..........................................................................................

E-3

 

Troubleshooting Guide ..........................................................................................

E-4

 

Troubleshooting Guide ..........................................................................................

E-5

 

________________________________________________________________________

 

Diagrams & Dimension Print ..........................................................................

Section F

 

________________________________________________________________________

 

Parts List ......................................................................................................

P411 Series

 

________________________________________________________________________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS - Ranger 250 ( K1725-2, K1725-4)

INPUT - GASOLINE ENGINE

Make/Model

Description

Horsepower

Operating

Displacement cu. in.(cu. cm)

Starting

Capacities

 

 

 

@ 3600 RPM

SPEED

Bore x Stroke in.(mm)

System

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

12VDC Battery

 

K1725-2

 

 

 

High

38 (624)

and starter

Fuel: 12gal.(45.4L)

 

 

 

 

Kohler CH20

2 Cylinder

20 HP

3.03x 2.64 (77x67)

 

Oil: 2.0qts.(1.9L)

3700RPM

 

OHV

 

 

Push Button

 

4 Cycle

 

Full Load

 

 

 

Air Cooled

 

 

 

Starter

 

K1725-4

Gasoline

 

3500RPM

 

 

 

Engine

 

Low Idle

39.9 (653)

Group 58 Battery

Fuel: 12gal.(45.4L)

Onan P220

 

 

20.5 HP

3.15x 2.56 (80x65)

(435 cold

 

 

2400RPM

OHV

 

 

 

 

 

crank amps)

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

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)

5% Regulation (Kohler)

 

 

 

 

 

 

 

 

Centrifugal Flywheel (Onan OHV)

 

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.

 

 

 

 

 

 

 

 

 

 

 

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

A-2

 

 

INSTALLATION

A-2

 

 

 

 

 

MACHINE SPECIFICATIONS - Ranger 250 (K1725-2, K1725-4)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RECEPTACLES

AUXILIARY POWER CIRCUIT BREAKER

OTHER CIRCUIT BREAKERS

 

 

 

 

(2)

120VAC Duplex (5-20R)

Two 20AMP for Two Duplex Receptacle

25AMP for Battery Charging Circuit

(1)

120/240VAC Dual Voltage

Two 40AMP for Dual Voltage

15AMP for 42V Wire Feeder Power

Full KVA (14-50R)

 

 

 

 

 

 

 

RANGER 250

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.

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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.

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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(1) is 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.

RANGER 250

A-4

INSTALLATION

A-4

 

 

 

5.Conformance with federal, state and local laws.(1)

(1)Consult applicable federal, state and local laws regarding specific requirements for use on public highways.

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

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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.

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.

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ENGINE COOLING SYSTEM

Air to cool the engine is drawn in lower set of louvers on the case back. It is important that the intake air is not restricted. Allow a minimum clearance of 2 feet (0.6m) from the case back to a vertical surface.

BATTERY CONNECTION

CAUTION

Use caution as the electrolyte is a strong acid that can burn skin and damage eyes.

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

The RANGER 250 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.

CAUTION

An incorrect spark arrester may lead to damage to the engine or adversely affect performance.

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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.

RANGER 250

A-5

INSTALLATION

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 .

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.

2)Be double insulated.

WARNING

Do not ground the machine to a pipe that carries explosive or combustible material.

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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.

The U.S. National Electrical Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.

WELDING TERMINALS

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

 

 

Cable Size for

 

 

 

 

 

250 Amps

 

 

 

 

 

 

100% Duty Cycle

 

 

 

0-100Ft. (0-31meters)

 

 

1 AWG

 

 

 

100-150 Ft. (30-46 meters)

 

 

1 AWG

 

 

 

150-200 Ft. (46-61 meters)

 

 

1/0 AWG

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TABLE A-1

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.

RANGER 250

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.

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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.

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.

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.

RANGER 250

A-7

INSTALLATION

A-7

 

 

 

CONNECTION OF RANGER 250 TO PREMISES WIRING

 

240 VOLT

 

GROUNDED CONDUCTOR

240 Volt

POWER

120 VOLT

60 Hz.

COMPANY

3-Wire

120 VOLT

Service

METER

 

 

NEUTRAL

 

BUS

DOUBLE POLE DOUBLE THROW

SWITCH RATING TO BE THE SAME

AS OR GREATER THAN PREMISES

SERVICE OVERCURRENT

PROTECTION.

50 AMP, 120/240

VOLT PLUG 240 VOLT NEMA TYPE 14-50

N

LOAD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PREMISES

 

 

 

 

 

 

 

 

 

 

 

DISCONNECT AND

 

 

 

 

 

 

 

 

 

 

 

SERVICE

 

 

 

GROUND

40AMP

 

OVERCURRENT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PROTECTION

240 VOLT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

DOUBLE

 

 

 

 

 

 

 

 

 

 

 

 

POLE

 

 

 

 

 

 

 

 

 

 

 

 

CIRCUIT

 

 

 

 

 

 

 

 

 

 

 

 

BREAKER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GND

N

50 AMP, 120/240 VOLT

RECEPTACLE 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

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 " position.

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

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

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

Connection of 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.

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.

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

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