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Lincoln Electric 250 manual

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Table of contents for the manual

  • Page 1

    Ranger 250 OPERA TOR’S MANUAL IM741-A April, 2003 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 [...]

  • Page 2

    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. ________________________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS 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[...]

  • Page 4

    FOR ELECTRICALL Y 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 C[...]

  • Page 5

    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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ?[...]

  • Page 6

    v v Thank You 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

  • Page 7

    vi vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .......................................................................................................A-1 Machine Specifications ......................[...]

  • Page 8

    vii vii T ABLE OF CONTENTS Maintenance ......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................[...]

  • Page 9

    Make/Model Description Horsepower Operating Displacement cu. in.(cu. cm) Starting Capacities @ 3600 RPM SPEED Bore x Stroke in.(mm) System RANGER 250 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 reduce[...]

  • Page 10

    A-2 INST ALLA TION RANGER 250 A-2 MACHINE SPECIFICA TIONS - 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 [...]

  • Page 11

    A-3 INST ALLA TION RANGER 250 A-3 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 FALLING EQUIPMENT can cause injury. • Do not lift this machine using lift bale if it is equipped with a heavy a[...]

  • Page 12

    A-4 INST ALLA TION RANGER 250 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-OPERA TION ENGINE SER VICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Stop engine and allow to coo[...]

  • Page 13

    A-5 INST ALLA TION RANGER 250 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 con- trol at the welder to remote control . The 14 pin connector is used to directly connect a wire feeder or TIG Module (K9[...]

  • Page 14

    A-6 INST ALLA TION RANGER 250 A-6 6. Check and tighten the connections periodically. • Loose connections will cause the output terminals to overheat. The terminals may eventually melt. • Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another. ------------------------------------[...]

  • Page 15

    A-7 INST ALLA TION RANGER 250 A-7 240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS. 240 VOLT GROUNDED CONDUCTOR 40AMP 240 VOLT DOU[...]

  • Page 16

    A-8 INST ALLA TION RANGER 250 A-8 CONNECTION OF LINCOLN ELEC- TRIC 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 [...]

  • Page 17

    B-1 OPERA TION RANGER 250 B-1 GENERAL DESCRIPTION The Ranger 250 is a gasoline engine powered DC multi-process welding power source and 120 / 240 volt AC power generator. The engine drives a genera- tor that supplies three phase power for the DC weld- ing circuit and single phase power for the AC auxiliary outlets. The DC welding control system use[...]

  • Page 18

    B-2 OPERA TION B-2 WELDING CONTROLS: 1. OUTPUT CONTROL: The CONTROL dial provides continuous control of the welding current or welding voltage depending on the selected welding mode. This control is not active in the CC-STICK, PIPE, and CV-WIRE modes when a remote control or wire feeder with remote control is connected to either the 6 pin or 14 pin[...]

  • Page 19

    B-3 OPERA TION B-3 5. GROUND STUD: (graphic) Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. 6. 14-PIN AMPHENOL: For attaching wire feeder control cables to the Ranger 250. Includes contactor closure circuit, auto-sensing remote control circuit, and 120V and 42V power. The remote contr[...]

  • Page 20

    B-4 OPERA TION B-4 Operating the starter motor for more than 5 sec- onds can damage the motor. If the engine fails to start, release the switch and wait 10 seconds before operation the starter again. Do NOT push the START button while the engine is running because this can damage the ring gear and/or the starter motor. NOTE: When starting a Ranger [...]

  • Page 21

    B-5 OPERA TION B-5 TIG WELDING The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the CONTROL dial is first set to the desired current and the tungsten is touched to the work. During the time the tungsten is touching the work there is very little voltage or current and, in general, no tung[...]

  • Page 22

    B-6 OPERA TION B-6 ARC GOUGING The Ranger 250 can be used for limited arc gouging. For optimal performance, set the MODE switch to CC- STICK and the ARC CONTROL to +10. Set the CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table. Electrode Diameter Current R[...]

  • Page 23

    C-1 ACCESSORIES C-1 RECOMMENDED OPTIONAL EQUIPMENT K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.). Order: K957-1 Trailer K958-1 Ball Hitch K958-2 Lunette Eye Hitch K9[...]

  • Page 24

    D-1 MAINTENANCE D-1 RANGER 250 KOHLER ENGINE (1) Service more frequently when used in dusty areas and/or at high ambient temperatures. SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • Remove guards only when necessary t[...]

  • Page 25

    D-2 MAINTENANCE D-2 ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining. • Remove the oil filler cap and dipstick. Remove the yellow cap from the oil drain valve and attach the flexible drain tube supplied with the machine. Push in and twist the drain valve counterclockwise. Pull the valve out and drain [...]

  • Page 26

    D-3 MAINTENANCE D-3 AIR FIL TER P APER ELEMENT 1. Loosen the cover retaining knob and remove the cover. 2. Remove the pre-cleaner from the paper element. 3. Remove the element cover nut, element cover, and paper element. 4. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged eleme[...]

  • Page 27

    D-4 MAINTENANCE D-4 FUEL FIL TER 1. Check the fuel filter for water accumulation or sedi- ment. 2. Replace the fuel filter if it is found with excessive water accumulation or sediment. ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop. BA TTER Y MAINTENANCE To access the [...]

  • Page 28

    D-5 MAINTENANCE D-5 RANGER 250 WELDER / GENERA T OR MAINTENANCE STORAGE: Store the RANGER 250 in clean, dry pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air. Do this at least once a week in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT: It’s nor- mal for the brushes and slip rings to [...]

  • Page 29

    E-1 TROUBLESHOOTING E-1 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 possi[...]

  • Page 30

    E-2 TROUBLESHOOTING E-2 RANGER 250 Observe all Safety Guidelines detailed throughout this manual 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 PROBLEMS (SY[...]

  • Page 31

    E-3 TROUBLESHOOTING E-3 RANGER 250 Observe all Safety Guidelines detailed throughout this manual 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 PROBLEMS (SY[...]

  • Page 32

    E-4 TROUBLESHOOTING E-4 RANGER 250 Observe all Safety Guidelines detailed throughout this manual 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 PROBLEMS (SY[...]

  • Page 33

    E-5 TROUBLESHOOTING E-5 RANGER 250 Observe all Safety Guidelines detailed throughout this manual 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 PROBLEMS (SY[...]

  • Page 34

    F-1 DIAGRAMS F-1 RANGER 250[...]

  • Page 35

    F-2 DIAGRAMS F-2 RANGER 250[...]

  • Page 36

    F-3 DIAGRAMS F-3 RANGER 250[...]

  • Page 37

    F-4 DIAGRAMS F-4 RANGER 250[...]

  • Page 38

    F-5 DIAGRAMS F-5 RANGER 250[...]

  • Page 39

    F-6 DIAGRAMS F-6 RANGER 250 or ser vice t his equi pm ent. On ly qualified personnel should install,use Keep away from m oving parts. Keep guards in place. MOVING PARTS can injure W ARNING Do not touch electrically live parts. before servicing. Disconnect NEGATIVE (-) Bat te ry lead Do not operate with panels open. ELECTRIC SH OCK can kill 14 PIN A[...]

  • Page 40

    F-7 DIAGRAMS F-7 RANGER 250[...]

  • Page 41

    F-8 DIAGRAMS F-8 RANGER 250[...]

  • Page 42

    F-9 DIAGRAMS F-9 RANGER 250[...]

  • Page 43

    F-10 DIAGRAMS F-10 RANGER 250[...]

  • Page 44

    F-11 DIAGRAMS F-11 RANGER 250[...]

  • Page 45

    F-12 DIAGRAMS F-12 RANGER 250 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number[...]

  • Page 46

    F-13 DIAGRAMS F-13 RANGER 250 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number[...]

  • Page 47

    CENTER OF GRA VITY WITH OIL IN ENGINE AND EMPTY FUEL T ANK TRUCK/UNDERCARRIA GE MOUNTING HOLES 41.20 17.50 19.50 42.10 20.80 "A" "B" 29.88 33.62 36.24 10.28 10.78 7.22 24.86 2.6 F-14 DIAGRAMS F-14 RANGER 250 DIMENSION PRINT RANGER 250 ONAN P220OHV 22.25 15.25 DIMENSION “ A ” DIMENSION “ B ” KOHLER CH20 23.50 15.50 8/00 M[...]

  • Page 48

    NOTES RANGER 250[...]

  • Page 49

    NOTES RANGER 250[...]

  • Page 50

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE PARA EL[...]

  • Page 51

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

  • Page 52

    • 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 •[...]