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Lincoln Electric IM931 manual

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Table of contents for the manual

  • Page 1

    Ranger 250 LPG OPERA TOR’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 M[...]

  • 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 LPG 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 re[...]

  • Page 10

    A-2 INST ALLA TION RANGER 250 LPG A-2 MACHINE SPECIFICA TIONS - RANGER 250 LPG Engine (K2336-2) RECEPTACLES 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 Fe[...]

  • Page 11

    A-3 INST ALLA TION RANGER 250 LPG A-3 • Lift only with equipment of ade- quate lifting capacity. • Be sure machine is stable when lifting. • Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder. FALLING • Do not lift machine if lift bail is EQUIPMENT can damaged. cause injury. •[...]

  • Page 12

    A-4 INST ALLA TION RANGER 250 LPG A-4 Be certain that the cylinder valve is CLOSED before attempting to attach the fuel supply hose coupler to the cylinder. Connect the coupler to the fuel cylinder and tighten by hand. ___________________________________________ After connecting the fuel supply to the supply cylinder, open the valve on the fuel cyl[...]

  • Page 13

    A-5 INST ALLA TION RANGER 250 LPG A-5 OIL The RANGER 250 LPG 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 run- ning time during the first 25 running hours. R[...]

  • Page 14

    A-6 INST ALLA TION RANGER 250 LPG A-6 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 [...]

  • Page 15

    A-7 INST ALLA TION RANGER 250 LPG A-7 AUXILIAR Y POWER RECEPT ACLES Start the engine and set the “IDLER” control switch to the “High Idle” mode. Voltage is now correct at the receptacles for auxiliary power. This must be done before a tripped GFCI receptacle can be reset proper- ly. See the MAINTENANCE section for detailed infor- mation on [...]

  • Page 16

    A-8 INST ALLA TION RANGER 250 LPG A-8 240 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[...]

  • Page 17

    A-9 INST ALLA TION RANGER 250 A-9 CONNECTION OF LINCOLN ELEC- TRIC WIRE FEEDERS Connection of LN-7 or LN-8 to the RANGER 250 LPG 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 requi[...]

  • Page 18

    A-10 INST ALLA TION RANGER 250 LPG A-10 Connection of Prince Spool Gun to the RANGER 250 LPG Connection of the Prince XL Spool Gun requires the use of the K1849-1 Adapter Module. 1. Shut the Welder off. 2. For electrode Positive, connect the electrode cable to the "+" terminal of the welder and work cable to the "-" terminal of [...]

  • Page 19

    B-1 OPERA TION RANGER 250 LPG B-1 GENERAL DESCRIPTION The RANGER 250 LPG is an 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 20

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

  • Page 21

    B-3 OPERA TION B-3 4. WELD OUTPUT TERMINALS WITH FLANGE NUT : Provides a connection point for the electrode and work cables. Output Stud covers porvided on code 11272 and above. 5. GROUND STUD: Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. 6. 14-PIN CONNECTOR: For attaching wire feed[...]

  • Page 22

    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. STOPPING Remove all welding a[...]

  • Page 23

    (1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases. (2) Tungsten electrodes are classified as follows by the American Welding Society (AWS): Pure EWP 1% Thoriated EWTh-1 2% Thoriated EWTh-2 Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a s[...]

  • Page 24

    B-6 OPERA TION B-6 ARC GOUGING The RANGER 250 LPG 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 Curren[...]

  • Page 25

    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 26

    D-1 MAINTENANCE D-1 RANGER 250 LPG 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 necessa[...]

  • Page 27

    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 28

    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 29

    D-4 MAINTENANCE D-4 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 battery, Remove the 2 screws from the rear battery tray using a screwdriver or a 3/8" socket. Slide the battery tray out only far enough to access the battery t[...]

  • Page 30

    D-5 MAINTENANCE D-5 GFCI RECEPT ACLE TESTING AND RESET- TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage. • If the equipment has been shut down,[...]

  • Page 31

    E-1 TROUBLESHOOTING E-1 RANGER 250 LPG 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 p[...]

  • Page 32

    E-2 TROUBLESHOOTING E-2 RANGER 250 LPG 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[...]

  • Page 33

    E-3 TROUBLESHOOTING E-3 RANGER 250 LPG 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[...]

  • Page 34

    E-4 TROUBLESHOOTING E-4 RANGER 250 LPG 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[...]

  • Page 35

    E-5 TROUBLESHOOTING E-5 RANGER 250 LPG 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[...]

  • 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

    F-6 DIAGRAMS F-6 RANGER 250 LPG or ser vice t his equi pm ent. On ly qualified personnel should install,use Keep away from movi ng pa rts. Keep guards in place. MOVING PART S can injure WA R N I N G Do not touch electrically live pa rts. before servicing. Disconnect NEGATI VE (- ) Battery lead Do not operate with panel s open. ELECTRIC SH OCK can k[...]

  • 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

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

  • Page 47

    M19 41 0 E CIRCU IT BREAKERS 41.2 0 17.5 0 19.5 0 TRUC K/U ND E RC A RR IAG E MOU NTING HOLE S 7.22 24.8 6 2.62 5.57 30.6 5 NOTE: CASE F RONT GRAPHI CS MAY NOT MAT CH ALL CODES. 42.1 0 20.8 0 10.2 8 10.7 8 29.8 8 33.6 2 36.2 4 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

    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 P ARA E[...]

  • 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 P ARA 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 [...]

  • 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 •[...]