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Lincoln Electric RANGER 250 LPG Operator'S Manual Download Page 1

Ranger 250 LPG

OPERATOR’S MANUAL

IM931

September, 2006

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 thought-
ful 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.

For use with machines having Code Numbers:

11424

• 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 Leader in Welding and Cutting Products •

Copyright © 2005 Lincoln Global Inc.

R

NRTL/C

Summary of Contents for RANGER 250 LPG

Page 1: ...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 For use with machines having Code Numbers 11424 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 Leade...

Page 2: ...R 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 availa...

Page 3: ...ter 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 FUMES AND GASES can be dangerous 5 a Welding may produ...

Page 4: ...event 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 Weldin...

Page 5: ...s 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 Eloign...

Page 6: ...tion below for future reference This information can be found on your machine nameplate Product _________________________________________________________________________________ Model Number ___________________________________________________________________________ Code Number or Date Code_________________________________________________________________ Serial Number______________________________...

Page 7: ...ections A 7 Premises Wiring A 8 Connection of Lincoln Electric Wire Feeders A 9 thru A 10 ________________________________________________________________________________ Operation Section B Safety Precautions B 1 General Description B 1 Design Features B 1 Engine Operation B 1 Welding Controls B 2 Engine Controls B 3 Starting and Stopping the Engine B 3 Stopping B 4 Welding Operation B 4 Duty Cyc...

Page 8: ...ance D 5 Storage D 5 Cleaning D 5 Brush Removal and Replacement D 5 GFCI Receptacle Testing and Setting Procedure D 5 ________________________________________________________________________ Troubleshooting Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 Troubleshooting Guide E 3 Troubleshooting Guide E 4 Troubleshooting Guide E 5 __________________________________________...

Page 9: ...aporizer 5 Regulation 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 RATED OUTPUT 104 F 40C GENERATOR 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 Am...

Page 10: ...CLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS 2 120VAC GFCI Two 20AMP for Two Duplex Receptacle 20AMP for Battery Charging Circuit Duplex 5 20R 1 120 240VAC Dual Voltage One 50AMP for Dual Voltage 2 pole 15AMP for 42V Wire Feeder Power Full KVA 14 50R RECEPTACLES AND CIRCUIT BREAKERS ...

Page 11: ...d local laws 1 1 Consult applicable federal state and local laws regarding spe cific requirements for use on public highways SAFETY PRECAUTIONS Only qualified personnel should install use or service this equipment LOCATION AND VENTILATION The welder should be located to provide an unrestrict ed flow of clean cool air to the cooling air inlets and to avoid restricting the cooling air outlets Also l...

Page 12: ...he engine operating and maintenance instructions supplied with this machine FUEL A lift truck type coupler is provided on the supplied fuel line for easy hand attachment to a lift truck type LPG fuel cylinder The fuel cylinder must meet D O T Specification 4E 240 The valve on the fuel cylinder must be installed on the outlet marked LIQUID The engine will not develop full power if connected to the ...

Page 13: ...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 main tained An incorrect s...

Page 14: ...ing stud marked with the symbol is provided on the front of the welder WELDING TERMINALS The RANGER 250 LPG is equipped with a toggle switch for selecting hot welding terminals when in the WELD TERMINALS ON position or cold weld ing terminals when in the REMOTELY CON TROLLED position WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output studs The welding pro...

Page 15: ... the associated receptacle NOTE The 240V receptacle has two 120V circuits but are of opposite polarities and cannot be paralleled STANDBY POWER CONNECTIONS The RANGER 250 LPG is suitable for temporary standby or emergency power using the engine manu facturer s recommended maintenance schedule The RANGER 250 LPG can be permanently installed as a standby power unit for 240 VAC 3 wire single phase 33...

Page 16: ...4 50 50 AMP 120 240 VOLT RECEPTACLE CONNECTION OF RANGER 250 LPG TO PREMISES 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 Ce...

Page 17: ... the wire will begin to feed and the welding process is started a Shut the welder off b For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the terminal of the welder c Across The Arc Model Attach the single lead from the front of the...

Page 18: ...ve connect the electrode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder For elec trode 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 suppl...

Page 19: ...ower than gasoline com bustion the exhaust from the Ranger 250 LPG can kill Avoid breathing of vapor Keep sparks and flame away from tank WARNING SAFETY PRECAUTIONS Read and understand this entire section before operating your RANGER 250 LPG Do not attempt to use this equipment until you have thoroughly read all operating and mainte nance manuals supplied with your machine They include important s...

Page 20: ...ts sticking of the electrode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with a setting at 0 DOWNHILL PIPE MODE In this mode the ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or a more forceful digging arc crisp Increasing the numb...

Page 21: ...s left in the RUN position and the engine is not operating 11 CHOKE When pulled out it closes the choke valve on the engine carburetor for quick starting 12 START PUSH BUTTON Energizes the starter motor to crank the engine 13 IDLER SWITCH Has two positions as follows 1 In the HIGH position the engine runs at the high idle speed controlled by the engine governor 2 In the AUTO position the idler ope...

Page 22: ...e MODE switch is designed for horizontal and vertical up welding with all types of electrodes especially low hydrogen The out put CONTROL dial adjusts the full output range for stick welding The ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or crisp arc Increasing the number from 10 soft to 10 crisp increases the short circuit current and pre v...

Page 23: ... The settings are for reference RANGER 250 LPG 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 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 ...

Page 24: ...acity All auxiliary power is protected by circuit breakers 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...

Page 25: ... machine when not in use K1898 1 SPARK ARRESTER Mounts inside exhaust pipe K704 ACCESSORY KIT 400 Amp Stick welding Accessory Kit Includes Headshield electrode cable holder work cable and work clamp K875 ACCESSORY KIT Includes 20Ft 6 1m 6 electrode cable 15Ft 4 6 6 work cable Headsheild FilterPlate Work Clamp and Electrode Holder K857 25 ft 7 5m or K857 1 100 ft 30 4m REMOTE CONTROL Portable contr...

Page 26: ...ools 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 make certain that the valve on the LPG fuel supply cylinder is closed Check the crankcase oil level and add oil if indicated WARNING ITEM MAKE AND PART NUMBER KOHLER CH730S ENGINE Oil Filter Kohler 12 050 01 Fram PH8172 Air Filter Element Kohl...

Page 27: ...il 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 fil ter socket tool to tighten the filter an additional 1 2 to 7 8 turn 5 Refill the crankcase with...

Page 28: ...ng spark plug the muffler becomes very hot during operation and remains hot for a while after stopping the engine Be care ful 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 plu...

Page 29: ...ded discon nect 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 bat tery compartment and surrounding areas with clear water Coat the battery termin...

Page 30: ... The light or other product should go ON again If the light or other product remains ON when the Test button is pushed the GFCI is not working prop erly or has been incorrectly installed miswired If your GFCI is not working properly contact a qualified certified electrician who can assess the situation rewire the GFCI if necessary or replace the device RANGER 250 LPG WELDER GENERATOR MAINTENANCE S...

Page 31: ...BLE 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 Author...

Page 32: ...ery does not stay charged 1 If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility 1 Battery is low 2 Loose battery cable connections 3 Faulty engine starter motor 4 Battery Circuit circuit breaker is tripped 1 LPG fuel cylinder empty 2 Faulty fuel solenoid or faulty PC board or ignition system 1 Lo...

Page 33: ...o 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 auxil iary power 3 Faulty PC board or idler sole noid 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 l...

Page 34: ...connected to 14 pin connector No auxiliary power 1 Poor work lead connection to work 2 Weld Terminals switch in wrong position 3 Faulty PC board or welder alter nator 1 Poor remote control cable con nection to 6 pin or 14 pin con nector 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 contr...

Page 35: ...ot stable or is not satisfactory the engine runs nor mally The auxiliary power is nor mal 1 Make sure the MODE selector switch is in the correct position for the process being used For example CV WIRE PIPE CC STICK 2 Make sure the electrode wire gas voltage current etc is cor rect for the process being used 3 Check for loose or faulty con nections at the weld output ter minals and welding cable co...

Page 36: ...F 1 DIAGRAMS F 1 RANGER 250 LPG ...

Page 37: ...F 2 DIAGRAMS F 2 RANGER 250 LPG ...

Page 38: ...F 3 DIAGRAMS F 3 RANGER 250 LPG ...

Page 39: ...F 4 DIAGRAMS F 4 RANGER 250 LPG ...

Page 40: ...F 5 DIAGRAMS F 5 RANGER 250 LPG ...

Page 41: ...NY 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 AN...

Page 42: ...F 7 DIAGRAMS F 7 RANGER 250 LPG ...

Page 43: ...F 8 DIAGRAMS F 8 RANGER 250 LPG ...

Page 44: ...F 9 DIAGRAMS F 9 RANGER 250 LPG ...

Page 45: ...F 10 DIAGRAMS F 10 RANGER 250 LPG ...

Page 46: ... 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: ... 50 19 50 TRUCK UNDERCARRIAGE MOUNTING HOLES 7 22 24 86 2 62 5 57 30 65 NOTE CASE FRONT GRAPHICS MAY NOT MATCH ALL CODES 42 10 20 80 10 28 10 78 29 88 33 62 36 24 23 50 15 50 15 50 F 12 DIMENSION PRINT F 12 RANGER 250 LPG RANGER 250 LPG ...

Page 48: ...NOTES RANGER 250 LPG ...

Page 49: ...NOTES RANGER 250 LPG ...

Page 50: ...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 moja da Aislese del trabajo y de la tierra 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 Elektrode...

Page 51: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing 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 öff nen Maschine anhalten Não opere co...

Page 52: ...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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