Lincoln Electric RANGER 225 Operator'S Manual Download Page 10

Page: 10 / 36

FUEL

Fill the fuel tank with clean, fresh, lead-free gasoline.
Observe fuel sight gauge in the base of the machine
while filling to prevent overfilling.

OIL

The  RANGER®  225  is  shipped  with  the  engine
crankcase  filled  with  SAE  10W-30  oil.  Check  the  oil
level before starting the engine. If it is not up to the full
mark  on  the  dip  stick,  add  oil  as  required.  Make  cer-
tain that the oil filler cap is tightened securely. Refer to
the engine Owner’s Manual for specific oil recommen-
dations.

bATTERY CONNECTIONS

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

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

This welder is shipped with the negative battery cable
disconnected. Make sure that the Engine Switch is in
the “STOP” position and attach the disconnected
cable securely to the negative battery terminal before
attempting to operate the machine. If the battery is
discharged and does not have enough power to start
the engine, see the battery charging instructions in the
Battery section.

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 bat-
tery with the correct polarity.

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; rough-

ness of surface on which the trailer will be operated;
environmental conditions.

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.

A-3

INSTALLATION

RANGER® 225

A-3

PRE-OPERATION SERVICE

READ the engine operating and maintenance
instructions supplied with this machine.

CAUTION

LUBRICATION SYSTEM CAPACITY

(INCLUDING FILTER)

Kohler CH23S - 2.0 Quarts (1.9 Liters)

• Damage to the fuel tank may cause

fire or explosion. Do not drill holes
in the RANGER® 225 base or weld
to the RANGER® 225 base.

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

WARNING

CAUTION

• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away from

tank.

• Do not leave unattended while

fueling.

• Wipe up spilled fuel and allow

fumes to clear before starting
engine.

• Do not overfill tank, fuel expan-

sion may cause overflow.

GASOLINE FUEL ONLY

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

WARNING

GASOLINE

can cause fire
or explosion.

VEHICLE MOUNTING

Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.

• Only transport this Equipment on serviceable

vehicles which are rated and designed for such
loads.

• Distribute, balance and secure loads so vehicle

is stable under conditions of use.

• Do not exceed maximum rated loads for compo-

nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of

vehicle.

• Follow vehicle manufacturer’s instructions.

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

WARNING

Summary of Contents for RANGER 225

Page 1: ...on and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful 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 World s Lea...

Page 2: ...AKER 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 ava...

Page 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 ii SAFETY ii FUMES AND GASES can be dangerous 5 a Welding may produce fu...

Page 4: ...reas 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 touc...

Page 5: ...riés 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 pan talons 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 Elo...

Page 6: ...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 linc...

Page 7: ...art in Shutdown Instructions B 3 Starting the Engine B 3 Safety Precautions B 3 Stopping the Engine B 3 Break In Period B 3 Welding Process B 4 Stick Constant Current Welding B 4 Scratch Start TIG Constant Current Welding B 4 Wire Feed Welding Processes Constant Voltage B 5 Arc Gouging B 5 Summary of Welding Processes B 5 ____________________________________________________________________________...

Page 8: ... equivalent to volt amperes at unity factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced RECEPTACLES 2 120VAC Duplex 5 20R 1 120 240VAC Dual Voltage Full KVA 14 50R bATTERY CHARGING CIRCUIT bREAKER 20AMP for Engine Battery Charging Circuit AUXILIARY POWER CIRCUIT bREAKER Two 20AMP for Two Duplex Receptacle 1 40AMP for Dual Vol...

Page 9: ...the welder SPARK ARRESTER Some federal state or local laws may require that gasoline 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 the K1898 1 spark arrester must be installed and prop...

Page 10: ...while being operated or serviced 4 Typical conditions of use i e travel speed rough ness of surface on which the trailer will be operated environmental conditions 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 A 3 INSTALLATION RANGER 225 A 3 PRE OPERATION SERVICE READ the engine operatin...

Page 11: ...n lifting the machine ADDITIONAL SAFETY PRECAUTION HIGH ALTITUDE OPERATION At higher altitudes Welder output de rating may be necessary For maximum rating de rate the welder output 3 5 for every 1000 ft 305m above 3000 ft 914m If operation will consistently be at altitudes above 5 000 ft 1525m a carburetor jet designed for high altitudes should be installed This will result in better fuel economy ...

Page 12: ...by setting the idle mode to HIGH NOTE LN 15 Control Cable model will not work with the RANGER 225 Position the RANGE switch to the WIRE FEED CV position Attach the single lead from the LN 25 control box to the work using the spring clip on the end of the lead it carries no welding current Place the engine switch in the AUTO IDLE posi tion When welding with MIG wire instead of self shielded core wi...

Page 13: ...e WELDER OPERATION WELDER OUTPUT Maximum Open Circuit Voltage at 3700 RPM is 80 Volts RMS Duty Cycle is the percentage of time the load is being applied in a 10 minute period For example a 60 duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period Duty Cycle for the RANGER 225 is 100 AUXILIARY POWER The RANGER 225 can provide up to 9 000 watts of 120 240 volts AC sin...

Page 14: ...WITHOUT ADDI TIONAL RESISTIVE TYPE LOADS Inductive Single phase induction motors These devices require large drills well pumps grinders small current inrush for starting refrigerators weed and hedge Some synchronous motors may trimmers be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures Capacitive Inductive Computers high resolution TV...

Page 15: ...ker Maximum rated load for the 240V auxiliary is 38 amperes Loading above 38 amperes will reduce output voltage below the allowable 10 of rated voltage which may damage appliances or other motor driven equipment 3 Install a 50 amp 120 240V plug NEMA type 14 50 to the Double Pole Circuit Breaker using No 8 4 conductor cable of the desired length The 50 amp 120 240V plug is available in the optional...

Page 16: ...onnection of RANGER 225 to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes Figure 1 CONNECTION OF RANGER 225 TO PREMISES WIRING WARNING ...

Page 17: ...eptacles the engine will accelerate to high speed If no power is being drawn from the receptacles and not welding for 10 14 seconds the idler reduces the engine speed to low idle b 1 OPERATION RANGER 225 b 1 SAFETY PRECAUTIONS 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 detai...

Page 18: ...ange Setting Current Range b 2 OPERATION b 2 RANGER 225 CAUTION KOHLER 23 H P COMMAND CH23S 40 Gallons Hour 1 50 Liters Hour 7 Gallons Hour 2 8 Liters Hour 1 3 Gallons Hour 4 9 Liters Hour 1 2 Gallons Hour 4 5 Liters Hour 1 4 Gallons Hour 5 3 Liters Hour Low Idle No Load 2400 RPM High Idle No Load 3700 RPM DC CC Weld Output 210 Amps 25 Volts DC CV Weld Output 200 Amps 20 Volts Auxiliary Power 9000...

Page 19: ...and allow engine to run at low idle speed for a few minutes to cool the engine Stop the engine by placing the Engine switch in the OFF position A fuel shut off valve is not required on the RANGER 225 because the fuel tank is mounted below the engine bREAK IN PERIOD It is normal for any engine to use a greater amount of oil until the break in is accomplished Check the oil level twice a day during t...

Page 20: ... 225 and any high frequency generating equip ment must be properly grounded See the K930 2 TIG Module operating manuals for complete instructions on installation operation and maintenance When using the TIG Module the OUTPUT control on the RANGER 225 is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if con nected to the TIG Module RANGER 225 90 MAX 145 MAX 225...

Page 21: ...SED MODE WELDING WELDING ELECTRODE SETTING CURRENT RANGE DC electrode positive 1 8 30 60 Amps 5 32 90 150 Amps 3 16 150 250 Amps ARC GOUGING The RANGER 225 can be used for limited arc goug ing Set the Range switch to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table When welding with MIG wire instead of self shielded cor...

Page 22: ... 225 when not in use Made from attractive red canvas material which is flame retardant mildew resistant and water repellent K802R Power Plug Kit provides four 120V plugs rated at 15 amps each and one dual voltage Full KVA plug rated at 120 240V 50 amps K802N Power Plug Kit Provides four 120V plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240V 50 amps K704 Accessory Kit...

Page 23: ...26 2 TIG Magnum TIG Torch K1783 4 TIG Torch KP509 Magnum Parts Kit and Argon Gas K930 2 TIG Module Provides high frequency and shield ing gas control for AC and DC GTAW TIG welding applica tions Its compact case is designed foe easy carrying com plete with a handle High frequency bypass is built in Requires K938 1 Contactor Kit K936 4 Control Cable and K814 Arc Start Switch K938 1 Contactor Kit Fo...

Page 24: ...gh temperature and other severe operating conditions Refer to the maintenance section of the Engine Owner s Manual for more information NOTE Engine life will be reduced if the oil and oil filter are not changed according to the manufacturer s recommendation 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 t...

Page 25: ... socket tool to tighten the filter an additional 1 2 to 7 8 turn 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 neces sary add oil to the upper limit mark on the dipstick AIR CLEANER AND OTHER MAINTENANCE Air Cleaner With normal operating conditions t...

Page 26: ...st and then the positive battery cable before attaching the charger leads Failure to do so can result in damage to the internal charger components When reconnecting the cables connect the positive cable first and the negative cable last HARDWARE Both English and Metric fasteners are used in this welder RANGER 225 WARNING GASES FROM bATTERY can explode Keep sparks flame and cigarettes away from bat...

Page 27: ...E 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 Authoriz...

Page 28: ...miscellaneous leads 2 Open lead in flashing or field circuit 3 Faulty rotor 4 Faulty Potentiometer R1 5 Faulty stator Field winding 6 Faulty Field rectifier On PCB 7 Faulty P C Board 1 Idler switch on High Idle 2 Insufficient voltage present on idler solenoid terminals Voltage should be 12V to 14V DC 3 External load on welder or auxiliary power 4 Faulty wiring in solenoid circuit 5 Faulty idler so...

Page 29: ...ine does not develop full power Engine is hard to start 1 No voltage signal from the current sensor 2 Auxiliary power load less than 100 to 150 watts 3 Faulty P C Board 1 Battery will not hold a charge Faulty Battery 2 No or insufficient charging current 3 Loose battery cable connection s 1 Out of fuel 2 Low oil level 1 Fuel filter clogged 2 Air filter clogged 1 Spark plugs do not have specified g...

Page 30: ... N D S C R E W I N S I D E R I G H T C A S E F R O N T F R A M E G R O U N D S T U D O N C A S E F R O N T 6 3 A 4 R E A C T O R S 1 R 1 R 4 R E A C T O R R 3 C 1 W 2 W 1 C 1 1 2 3 4 E N G I N E C O N T R O L S W I T C H O F F A U T O H I G H S T A R T 1 2 3 4 X X X X X X X X X C L O S E D C I R C U I T C C W P O S I T I V E N E G A T I V E B 1 B 2 STARTER CR1 STARTER SOLENOID 12 VOLT IDLER SOLENO...

Page 31: ...F 2 DIAGRAMS F 2 RANGER 225 ...

Page 32: ...L I N E N G I N E A N D E M P T Y F U E L T A N K 2 1 4 4 2 0 8 0 4 2 1 0 3 3 6 2 3 6 2 4 1 0 2 7 1 0 7 8 N O T E C A S E F R O N T G R A P H I C S M A Y N O T M A T C H A L L C O D E S M22195 A 01 C C I I R R CU CUI I T T B B R R E E AKE AKER R S S 41 20 17 50 19 50 14 13 TRUCK UNDERCARRIAGE MOUNTING HOLES 24 86 2 6 7 22 29 88 CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK 21 44 20 80 4...

Page 33: ...NOTES RANGER 225 ...

Page 34: ...ch electrically live parts or electrode with skin or wet cloth ing l Insulate yourself from work and ground l No toque las partes o los electro dos bajo carga con la piel o ropa mojada l Aislese del trabajo y de la tierra l Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension l Isolez vous du travail et de la terre l Berühren Sie keine stromführen den Tei...

Page 35: ...von Schweibrauch l Sorgen Sie für gute Be und Entlüftung des Arbeitsplatzes l Mantenha seu rosto da fumaça l Use ventilação e exhaustão para l Turn power off before servicing l Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio l Débranchez le courant avant l en tretien l Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten ...

Page 36: ...s 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 World s Leader in Welding and Cutting Products ...

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