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TROUBLESHOOTING

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RANGER® 250

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.

CAUTION

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 (SYMP-
TOMS)”. 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.

HOW TO USE TROUBLESHOOTING GUIDE

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.

__________________________________________________________________________

WARNING

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Содержание Ranger 250

Страница 1: ... PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 11401 11421 11422 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 Lincoln Global Inc This man...

Страница 2: ... 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 availab...

Страница 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...

Страница 4: ... 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 wel...

Страница 5: ...propriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile 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 lʼon pique le laitier 6...

Страница 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...

Страница 7: ...s A 6 Premises Wiring A 7 Connection of Lincoln Electric Wire Feeders A 8 A 9 ________________________________________________________________________________ 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 Duty Cycle ...

Страница 8: ...y Maintenance D 4 Option Spark Arrestor D 4 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 ________________________...

Страница 9: ...cle Max OCV 3700 RPM CC STICK PIPE DC Output 28 Volts at 250 Amps 100 STICK PIPE Output Range 40 to 250 Amps TIG Output Range 20 to 250 Amps 60 Volts CV WIRE DC Output 28 Volts at 250 Amps 100 CV WIRE DC Output 27 Volts at 275 Amps 60 CV WIRE Output Range 14 to 28 volts Auxiliary Power 1 10 500 Watts Peak 9500 Watts Continuous 60 Hz 120 240 Volts PHYSICAL DIMENSIONS ENGINE COMPONENTS K1725 10 11 K...

Страница 10: ...EPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS 2 120VAC Duplex 5 20R Two 20AMP for Two Duplex Receptacle 20AMP for Battery Charging Circuit 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 ...

Страница 11: ...welder output 2 Volts for every 50 F 10 C above 104 F 40 C 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 locate the welder so that the engine exhaust fumes are prop erly ve...

Страница 12: ...ollow vehicle manufactureʼs instructions PRE OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc tions supplied with this machine 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 hou...

Страница 13: ...tches 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 wi...

Страница 14: ...20 VAC branch circuits these circuits cannot be paralleled Output voltage is within 10 at all loads up to rated capacity All auxiliary power is protected by circuit breakers The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insu lated tools with two wire plugs The current rating of any plug used with the system must be at least equal t...

Страница 15: ...4 50 50 AMP 120 240 VOLT RECEPTACLE CONNECTION OF RANGER 250 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 Certai...

Страница 16: ...15 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 Set the WELD TERMINALS switch to WELD TER MINALS ON Control Cable Model Connect Control Cable between Engine Welder and Feeder Set the WELD TERMINALS switch to REMOTELY CONTROLLED Set the MODE switch to the CV WIRE position Set the WIRE FEEDER ...

Страница 17: ...gger is closed the current sens ing 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 weld ing is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed Connection of LN 742 K487 25 Spool Gun and Cobramatic to Ranger 250 1 Shut the welder off 2 Connect per instruc...

Страница 18: ...2 Fill the tank approximately 4 inches 100mm from the top of the filler neck to allow for fuel expansion DO NOT FILL THE TANK TO THE POINT OF OVERFLOW 3 Replace the fuel cap and tighten securely 4 See Engine Ownerʼs Manual for specific fuel rec ommendations WARNING SAFETY PRECAUTIONS Read and understand this entire section before operating your Ranger 250 Do not attempt to use this equipment until...

Страница 19: ...ents sticking of the electrode to the plate while welding This can also increase spatter It is recom mended 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 CON TROL 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 ...

Страница 20: ...KE 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 operates as follows When switched from HIGH to AUTO or after startin...

Страница 21: ...GER 250 FUEL CONSUMPTION 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 flat horizontal and vertical up welding with all types of elec trodes especially low hydrogen The output CONTROL dial adjusts the full ...

Страница 22: ...ding 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 con trol The proper setting depends on the procedure and oper ator preference Start with the dial set at 0 Listed below are some wires suitable for use on this machine Innershield...

Страница 23: ... 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 paral...

Страница 24: ...able and 30 ft 9 1m of work cable head shield work clamp electrode holder Cables are rated at 400 amps 100 duty cycle K857 25 ft 7 5m or K857 1 100 ft 30 4m REMOTE CON TROL 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 K1690 1 GFCI RECEPTACLE KIT Includes one UL approved 120V ground fault circuit interrup...

Страница 25: ...Hours Every 100 Hours Every 100 Hours Every 100 Hours Every 200 Hours Every 200 Hours MAINTENANCE REQUIRED Fill fuel tank Check oil level Check air cleaner for dirty loose or dam aged parts Check air intake and cooling areas clean as necessary First Oil Change Service air pre cleaner Change engine oil 1 Replace fuel filter element Clean or replace air filter element 1 Spark Arrester Replace oil fi...

Страница 26: ... ground or down a drain OIL FILTER CHANGE 1 Drain the engine oil 2 Remove the oil filter and drain the oil into a suitable container Discard the used oil filter 3 Clean the filter mounting base and coat the gasket of the new oil filter with clean engine oil 4 Screw on the new oil filter by hand until the gasket contacts the filter mounting base then use an oil filter socket tool to tighten the fil...

Страница 27: ... 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 plug 4 Visually inspect the spark pl...

Страница 28: ...y clean by wiping it with a damp cloth when dirty If the terminals appear corroded 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 1 liter 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 te...

Страница 29: ...nd slip rings to wear and darken slightly Inspect the brushes when a generator over haul is necessary Do not attempt to polish slip rings while the engine is running Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equip ment may result in danger to the technician and machine operator and will invalidate your factory w...

Страница 30: ...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...

Страница 31: ...attery 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 Out of fuel 2 Faulty fuel solenoid or faulty PC board or ignition system 3 Fuel pump n...

Страница 32: ...ng 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 less than 100 watts 2 Faulty ...

Страница 33: ...rk 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 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 3 Faulty wire feeder 1 Open circuit break...

Страница 34: ... 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 con ...

Страница 35: ... 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 ...

Страница 36: ...F 2 DIAGRAMS F 2 RANGER 250 ...

Страница 37: ...F 3 DIAGRAMS F 3 RANGER 250 ...

Страница 38: ...F 4 DIAGRAMS F 4 RANGER 250 ...

Страница 39: ...F 5 DIAGRAMS F 5 RANGER 250 ...

Страница 40: ...F 6 DIAGRAMS F 6 RANGER 250 ...

Страница 41: ... 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 ...

Страница 42: ...F 8 DIAGRAMS F 8 RANGER 250 ...

Страница 43: ...F 9 DIAGRAMS F 9 RANGER 250 ...

Страница 44: ...F 10 DIAGRAMS F 10 RANGER 250 2 9 03 ...

Страница 45: ...F 11 DIAGRAMS F 11 RANGER 250 ...

Страница 46: ...DERCARRIAGE MOUNTING HOLES 7 22 183 3 24 86 631 3 2 62 66 5 23 50 596 9 15 50 393 7 CENTER OF GRAVITY 29 80 756 9 NOTE CASE FRONT GRAPHICS MAY NOT MATCH ALL CODES 42 10 1069 5 20 80 528 3 10 28 261 0 10 78 273 9 33 62 854 0 36 24 920 4 F 12 DIMENSION PRINT F 12 RANGER 250 ...

Страница 47: ...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...

Страница 48: ... 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 entretien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Страница 49: ...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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