RETURN TO MAIN MENU
IM931
September, 2006
Ranger 250 LPG
For use with machines having Code Numbers:
11424
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.
R
NRTL/C
OPERATOR’S MANUAL
Copyright © 2005 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• 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
Download from Www.Somanuals.com. All Manuals Search And Download.
ii
ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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.
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
3.g. Never dip the electrode in water 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.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
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.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
Download from Www.Somanuals.com. All Manuals Search And Download.
iii
iii
SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
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.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
powered equipment.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
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.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
Download from Www.Somanuals.com. All Manuals Search And Download.
iv
iv
SAFETY
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.
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:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
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.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
Download from Www.Somanuals.com. All Manuals Search And Download.
v
v
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!
Thank You
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially 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.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
Download from Www.Somanuals.com. All Manuals Search And Download.
vi
vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Machine Specifications ........................................................................................................A-2
Safety Precautions. ..............................................................................................................A-3
Location and Ventilation................................................................................................A-3
Stacking ........................................................................................................................A-3
Angle of Operation ........................................................................................................A-3
Lifting.............................................................................................................................A-3
Additional Safety Precautions .......................................................................................A-3
High Altitude Operation.................................................................................................A-3
High Temperature Operation ........................................................................................A-3
Towing...........................................................................................................................A-3
Vehicle Mounting...........................................................................................................A-4
Pre-Operation Engine Service..............................................................................................A-4
Fuel ...............................................................................................................................A-4
Oil..................................................................................................................................A-5
Engine Coolant..............................................................................................................A-5
Battery Connections......................................................................................................A-5
Muffler Outlet Pipe ........................................................................................................A-5
Spark Arrester...............................................................................................................A-5
High Frequency Generators for TIG Applications .........................................................A-5
Remote Control.............................................................................................................A-5
Electrical Connections..........................................................................................................A-6
Machine Grounding.......................................................................................................A-6
Welding Terminals ........................................................................................................A-6
Welding Output Cables .................................................................................................A-6
Cable Installation...........................................................................................................A-6
Auxiliary Power Receptacles and Plugs...............................................................................A-7
Standby Power Connections................................................................................................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 Cycle.....................................................................................................................B-4
DC Stick Welding ..........................................................................................................B-4
Constant Current (Stick) Welding..................................................................................B-4
Pipe Welding.................................................................................................................B-4
Fuel Consumption.........................................................................................................B-4
TIG Welding ..................................................................................................................B-5
Wire Welding-CV...........................................................................................................B-5
Typical Current Ranges for Tungsten Electrodes .........................................................B-5
Arc Gouging ..................................................................................................................B-6
Auxiliary Power .............................................................................................................B-6
Simultaneous Welding and Auxiliary Power Loads.......................................................B-6
Extension Cord Recommendations...............................................................................B-6
________________________________________________________________________________
Accessories.....................................................................................................Section C
Recommended Optional Equipment.....................................................................C-1
________________________________________________________________________
Download from Www.Somanuals.com. All Manuals Search And Download.
vii
vii
TABLE OF CONTENTS
Maintenance......................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance......................................................................................D-1
Engine Maintenance Components ........................................................................D-1
Engine Oil Change..........................................................................................D-2
Engine Oil Refill Capacities ............................................................................D-2
Oil Filter Change.............................................................................................D-2
Air Cleaner Service.........................................................................................D-2
Air Pre-Cleaner Service ..................................................................................D-2
Air Filter Paper Element..................................................................................D-3
Spark Plug ......................................................................................................D-3
Spark Plug Service .........................................................................................D-3
Engine Adjustment..........................................................................................D-4
Battery Maintenance .......................................................................................D-4
Servicing Optional Spark Arrestor ...................................................................D-4
Welder / Generator Maintenance ........................................................................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
________________________________________________________________________
Diagrams & Dimension Print..........................................................................Section F
________________________________________________________________________
Parts List .....................................................................................................P-489 Series
________________________________________________________________________
Download from Www.Somanuals.com. All Manuals Search And Download.
A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - RANGER 250 LPG (K2336-2)
INPUT - LPG ENGINE
Make/Model Description Horsepower Operating Displacement cu. in.(cu. cm) Starting
Capacities
@ 3600 RPM SPEED Bore x Stroke in.(mm)
System
12VDC Battery
and starter
High
2 Cylinder
3700RPM
Kohler
CH730S
OHV
Fuel: LPG
Cylinder
Oil: 2.0Qts.(1.9L)
Push Button
Starter
4 Cycle
25 HP
Full Load
3500RPM
44 (725)
3.27x 2.64 (83x67)
Air Cooled
LPG
Engine
Group 58 Battery
(435 cold
crank amps)
Low Idle
2400RPM
RATED OUTPUT @ 104°F(40C°) - WELDER
Welding Output
Volts at Rated Amps
Duty Cycle Max.
OCV @ 3700 RPM
CC STICK & PIPE DC Output
STICK / PIPE Output Range
TIG Output Range
28 Volts at 250 Amps
100%
40 to 250 Amps
20 to 250 Amps
60 Volts
CV WIRE DC Output
28 Volts at 250 Amps
27 Volts at 275 Amps
14 to 28 volts
100%
60%
CV WIRE DC Output
CV WIRE Output Range
RATED OUTPUT @ 104°F(40C°) - GENERATOR
1
Auxiliary Power
10,500 Watts Peak, 9,500 Watts Continuous, 60 Hz
120/240 Volts
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
DEPTH
WEIGHT
30.00** in.
762.0 mm
21.50 in.
546.0 mm
42.25 in.
1073.0 mm
482 lbs. (218kg.)
**Top of enclosure, add 6.0” (152mm) for exhaust.
ENGINE COMPONENTS
LUBRICATION
Full Pressure
with Full Flow Filter
VALVE LIFTERS
FUEL SYSTEM
LPG regulator and
vaporizer
GOVERNOR
Mechanical Governor
5% Regulation (Kohler)
Hydraulic- (Kohler)
AIR CLEANER
ENGINE IDLER
MUFFLER
ENGINE PROTECTION
Shutdown on low oil
pressure.
Low noise Muffler: Top outlet
can be rotated. Made from
long life, aluminized steel.
Dual Element
Automatic Idler
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 reduced.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
A-2
A-2
INSTALLATION
MACHINE SPECIFICATIONS - RANGER 250 LPG Engine (K2336-2)
RECEPTACLES AND CIRCUIT BREAKERS
RECEPTACLES
AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS
Two 20AMP for Two Duplex Receptacle 20AMP for Battery Charging Circuit
(2) 120VAC GFCI
Duplex (5-20R)
(1) 120/240VAC Dual Voltage
Full KVA (14-50R)
One 50AMP for Dual Voltage (2-pole)
15AMP for 42V Wire Feeder Power
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
A-3
A-3
INSTALLATION
SAFETY PRECAUTIONS
WARNING
WARNING
• Lift only with equipment of ade-
quate lifting capacity.
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, detailed engine
starting, operating and maintenance instructions,
and parts lists.
• 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.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
FALLING
• Do not lift machine if lift bail is
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
------------------------------------------------------------------------
• Use in open, well ventilated areas or
vent exhaust outside.
HIGH ALTITUDE OPERATION
The Ranger 250 LPG requires no adjustment for high
altitude.
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
HIGH TEMPERATURE OPERATION
At temperatures above 40°C, output de-rating is nec-
essary. For maximum output ratings, de-rate the
welder output 2Volts for every 10°C above 40°C.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
• See additional warning information at
TOWING
front of this operator’s manual.
The recommended trailer for use with this equipment
-----------------------------------------------------------
(1)
for road, in-plant and yard towing by a vehicle is
• Only qualified personnel should install,
Lincoln’s K957-1. If the user adapts a non-Lincoln
trailer, the user must assume responsibility that the
method of attachment and usage does not result in a
safety hazard nor damage the welding equipment.
Some of the factors to be considered are as follows:
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 vented to an outside area.
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
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.
STACKING
Ranger 250 LPG machines cannot be stacked.
ANGLE OF OPERATION
Engines are designed to run in the level condition
which is where the optimum performance is achieved.
The maximum angle of continuous operation is 15
degrees in any direction. If the engine is to be operat-
ed at an angle, provisions must be made for checking
and maintaining the oil level at the normal (FULL) oil
capacity in the crankcase.
4. Typical conditions of use, i.e., travel speed; rough-
ness of surface on which the trailer will be operat-
ed; environmental conditions.
(1)
5. Conformance with federal, state and local laws.
(1) Consult applicable federal, state and local laws regarding spe-
cific requirements for use on public highways.
LIFTING
The RANGER 250 LPG weighs approximately 482
lbs. (218Kg.). A lift bail is mounted to the machine and
should always be used when lifting the machine.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
A-4
A-4
INSTALLATION
VEHICLE MOUNTING
CAUTION
WARNING
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
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.
• Use appropriate nuts bolts and lockwashers to
attach the equipment base to the metal bed or
frame of vehicle.
and tighten by hand.
___________________________________________
After connecting the fuel supply to the supply cylinder,
open the valve on the fuel cylinder and leak test by
brushing a 50/50 soap and water solution on to the fol-
lowing connections:
• Both ends of the fuel hose where it enters the metal connector.
• The threaded fitting on the end of fuel hose attached to the
Ranger 250 LPG fuel shut off solenoid.
• The fuel hose coupler and the connection to the cylinder valve.
• The stem of the cylinder valve and where the valve is attached
to the top of the cylinder.
• Follow vehicle manufacturer’s instructions.
------------------------------------------------------------------------
• All other fittings on top of the fuel cylinder.
PRE-OPERATION SERVICE
If growing bubbles appear, there is a leak. Re-tighten
connection or replace defective component. Retest to
make sure that there is no leak.
CAUTION
READ the engine operating and maintenance
instructions supplied with this machine.
Leak test must be performed each time the fuel cylin-
der is replaced.
WARNING
fuel can cause fire or explosion.
LPG
-
Always close the cylinder valve when the machine is
not being used.
• All leak testing must be done in a
well ventilated area free from all
potential ignition sources.
The specification for aluminum lift truck cylinders are
shown below:
• Keep sparks and flame away from machine
and LPG supply cylinder.
• Do not expose the LPG supply cylinder to
temperatures exceeding 120°F (49°C).
• Do not weld on or near the LPG supply cylin-
der.
• Do not smoke or allow any potential ignition
sources near the LPG supply cylinder.
•
Always be certain that the LPG supply cylinder is
NOT in the welding circuit. Do not allow either
welding cable to come in contact with the supply
cylinder.
• Replace the fuel supply hose if there is
excessive abrasion, cracks or wear or if the
hose is cut.
------------------------------------------------------------------------
Capacity
LP-Gas
(LBS.)
33.5
Cylinder
Volume
(Cu. In.)
2219
Weight
Empty
(LBS.)
22.5
Foot ring
Outside
Diameter
9 3/8”
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 vapor outlet.
43.5
2873
25.5
9 3/8”
Note: The Ranger 250 LPG cannot be used with vapor
draw LP gas cylinders such as those used for
recreation vehicles, trailers, grills, and boats.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
A-5
OIL
A-5
INSTALLATION
CAUTION
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. Refer to
the engine Operator’s Manual for specific oil recom-
mendations and break-in information. The oil change
interval is dependent on the quality of the oil and the
operating environment. Refer to the Engine Operator’s
Manual for the proper service and maintenance inter-
vals.
An incorrect spark arrester may lead to damage to
the engine or adversely affect performance.
------------------------------------------------------------------------
HIGH FREQUENCY GENERATORS FOR
TIG APPLICATIONS
The K930-2 TIG Module is suitable for use with the
RANGER 250 LPG. The RANGER 250 LPG and any
high frequency generating equipment must be proper-
ly grounded. See the K930-2 Operating Manual for
completed instructions on installation, operation, and
maintenance.
REMOTE CONTROL
ENGINE COOLING SYSTEM
Air to cool the engine is drawn in lower set of louvers
on the case back. It is important that the intake air is
not restricted. Allow a minimum clearance of 2 feet
(0.6m) from the case back to a vertical surface.
BATTERY CONNECTION
The RANGER 250 LPG is equipped with a 6 pin and a
14-pin connector. The 6-pin connector is for connect-
ing the K857 or K857-1 Remote Control (optional) or
for TIG welding, the K870 foot Amptrol or the K963-3
hand Amptrol.
CAUTION
When in the CC-STICK, DOWNHILL PIPE, and CV-
WIRE modes or when a remote control is connected
to the 6-pin connector, the auto-sensing circuit in the
RANGER 250 LPG automatically switches the OUT-
PUT control from control at the welder to remote con-
trol .
Use caution as the electrolyte is a strong acid that
can burn skin and damage eyes.
------------------------------------------------------------------------
The RANGER 250 LPG is shipped with the negative
battery cable disconnected. Make certain that the
RUN-STOP switch is in the STOP position. Remove
the two screws from the rear battery tray using a
screwdriver or a 3/8" socket. Attach the negative bat-
tery cable to the negative battery terminal and tighten
using a 1/2" socket or wrench.
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 LPG auto-
sensing circuit automatically makes the RANGER 250
LPG Output Control inactive and the remote voltage
control active when the control cable is connected to
the 14 pin connector.
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.
When in the TOUCH START TIG mode and when a
Amptrol is connected to the 6 Pin connector the OUT-
PUT dial is used to set the maximum current range of
the CURRENT CONTROL of the Amptrol.
------------------------------------------------------------------------
MUFFLER OUTLET PIPE
Using the clamp provided secure the outlet pipe to the
outlet tube with the pipe positioned such that it will
direct the exhaust in the desired direction. Tighten
using a 9/16" socket or wrench.
NOTE: When a wire feeder with a built in welding volt-
age control is connected to the 14 pin connector, do
not connect anything to the 6 pin connector.
SPARK ARRESTER
Some federal, state or local laws 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.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
A-6
A-6
INSTALLATION
ELECTRICAL CONNECTIONS
WELDING OUTPUT CABLES
With the engine off connect the electrode and work
cables to the output studs. The welding process dic-
tates the polarity of the electrode cable. These con-
nections should be checked periodically and tightened
with a 3/4" wrench.
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.)
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:
TABLE A-1
1) Be grounded to the frame of the welder using a
grounded type plug.
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
2) Be double insulated.
Cable Size for
Cable Length
250 Amps
100% Duty Cycle
WARNING
Do not ground the machine to a pipe that carries
explosive or combustible material.
2
1 AWG (35mm )
0-100Ft. (0-31meters)
2
1 AWG (35mm )
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
------------------------------------------------------------------------
When this welder is mounted on a truck or trailer, its
frame must be electrically bonded to the metal frame
of the vehicle. Use a #8 or larger copper wire connect-
ed between the machine grounding stud and the
frame of the vehicle. When this engine driven welder
is connected to premises wiring such as that in a
home or shop, its frame must be connected to the
system earth ground. See further connection instruc-
tions in the section entitled "Standby Power
Connections" as well as the article on grounding in the
latest U.S. National Electrical Code and the local
code.
2
1/0 AWG (50mm )
CABLE INSTALLATION
Install the welding cables to your RANGER 250 LPG
as follows.
1. The engine must be OFF to install welding cables.
2. Remove the flanged nuts from the output terminals.
3. Connect the electrode holder and work cables to
the weld output terminals. The terminals are identi-
fied on the case front.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into
the ground for at least ten feet and having no insulat-
ed joints, or to the metal framework of a building
which has been effectively grounded.
The U.S. National Electrical Code lists a number of
alternate means of grounding electrical equipment. A
machine grounding stud marked with the symbol
is provided on the front of the welder.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding (the
“work”) is properly connected to the work clamp and
cable.
6. Check and tighten the connections periodically.
• Loose connections will cause the output terminals
to overheat. The terminals may eventually melt.
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.
CAUTION
• Do not cross the welding cables at the output
terminal connection. Keep the cables isolated
and separate from one another.
------------------------------------------------------------------------
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
A-7
A-7
INSTALLATION
2. Take necessary steps to assure load is limited to
the capacity of the RANGER 250 LPG by installing
a 40 amp, 240 VAC double pole circuit breaker.
Maximum rated load for each leg of the 240 VAC
auxiliary is 33 amperes.
AUXILIARY POWER RECEPTACLES
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 testing and resetting the GFCI receptacle.
Loading above the rated output will reduce output
voltage below the allowable - 10% of rated voltage
which may damage appliances or other motor-dri-
ven equipment and may result in overheating of the
RANGER 250 LPG engine and/or alternator wind-
ings.
The auxiliary power of the RANGER 250 LPG con-
sists of two 20 Amp-120 VAC (5-20R)GFCI duplex
receptacles and one 50 Amp 120/240 VAC (14-50R)
receptacle. The 240 VAC receptacle can be split for
single phase 120 VAC operation.
3. Install a 50 amp, 120/240 VAC plug (NEMA Type
14-50) to the double-pole circuit breaker using No.
6, 4 conductor cable of the desired length. (The 50
amp, 120/240 VAC plug is available in the optional
K802R plug kit or as part number T12153-9.)
The auxiliary power capacity is 9,000 Watts Peak,
8000 Watts Continuous of 60 Hz, single phase power.
The auxiliary power capacity rating in watts is equiva-
lent to volt-amperes at unity power factor. The max
permissible current of the 240 VAC output is 33 Amps.
The 240 VAC output can be split to provide two sepa-
rate 120 VAC outputs with a max permissible current
of 33 Amps per output to two separate 120 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.
4. Plug this cable into the 50 Amp, 120/240 Volt
receptacle on the RANGER 250 LPG case front.
The 120V 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 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 amp service. Connections must be made
by a licensed electrician who can determine how the
120/240 VAC power can be adapted to the particular
installation and comply with all applicable electrical
codes.
1. Install the double-pole, double-throw switch
between the power company meter and the premis-
es disconnect. Switch rating must be the same or
greater than the customer’s premises disconnect
and service over current protection.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
A-8
A-8
INSTALLATION
CONNECTION OF RANGER 250 LPG TO PREMISES
240 VOLT
GROUNDED CONDUCTOR
POWER
240 Volt
60 Hz.
3-Wire
Service
120 VOLT
COMPANY
120 VOLT
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GROUND
40AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
240 VOLT
BREAKER
GND
N
50 AMP, 120/240 VOLT
RECEPTACLE
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
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. Certain state and local
laws require the premises to be isolated before the generator is linked to the premises. Check your
state and local requirements.
•A double pole, double throw transfer switch in conjunction with the properly rated double throw cir
cuit breaker is connected between the generator power and the utility meter.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
A-9
A-9
INSTALLATION
CONNECTION OF LINCOLN ELEC-
TRIC WIRE FEEDERS
e. Across-The-Arc Model:
Set the "WELD TERMINALS" switch to
"WELD TERMINALS ON"
Connection of LN-7 or LN-8 to the RANGER 250
LPG
Control Cable Model:
Set the "WELD TERMINALS" switch to
"REMOTELY CONTROLLED"
1. Shut the welder off.
f. Set the "WIRE FEEDER VOLTMETER" switch to
either "+" or "-" as required by the electrode polarity
being used.
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 by the electrode being
used.
g. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
h. Set the "IDLE" switch to the "AUTO IDLE" position.
4. Set the "MODE" switch to the "CV WIRE " posi-
tion.
5. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
6. Set the "WELD TERMINALS" switch to the
"REMOTELY CONTROLLED" position.
7. Set the "IDLE" switch to the "HIGH" position.
Connection of LN-15 Wire Feeder to the RANGER
250 LPG
These connections instructions apply to both the LN-
15 Across-The-Arc and Control Cable models. The
LN-15 has an internal contactor and the electrode is
not energized until the gun trigger is closed. When the
gun trigger is closed 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 LN-
15 to work using the spring clip at the end of
the lead. This is a control lead to supply cur-
rent to the wire feeder motor; it does not carry
welding current.
Control Cable Model:
Connect Control Cable between Engine
Welder and Feeder.
d. Set the MODE switch to the "CV-WIRE " position.
RANGER 250
Download from Www.Somanuals.com. All Manuals Search And Download.
A-10
A-10
INSTALLATION
Connection of Prince Spool Gun to the RANGER
250 LPG
Connection of the LN-25 to the RANGER 250 LPG
The LN-25 with or without an internal contactor may be
used with the RANGER 250 LPG. See the appropriate
connection diagram in Section F.
Connection of the Prince XL Spool Gun requires the
use of the K1849-1 Adapter Module.
1. Shut the Welder off.
Note: The LN-25 (K431) Remote Control Module and
(K432) Remote Cable are not recommended for use with
the RANGER 250 LPG.
2. 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.
1. Shut the welder off.
2. For electrode Positive, 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. Connect the Control Cable of the Spool Gun to the
Adapter Module and connect the Control Cable of
the Adapter Module to the Welder.
4. Connect the Gas Hose.
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 supply current to the wire feeder
motor; it does not carry welding current.
5. Set the MODE switch to the "CV-WIRE " position.
6. Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON"
7. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
4. Set the MODE switch to the "CV-WIRE " position.
5. Set the "WELD TERMINALS" switch to "WELD TER-
MINALS ON"
8. Set the "IDLE" switch to the "High" position.
6. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
7. Set the "IDLE" switch to the "AUTO" position. When
not welding, the RANGER 250 LPG engine will be at
the low idle speed. If you are using an LN-25 with an
internal contactor, the electrode is not energized until
the gun trigger is closed.
8. When the gun trigger is closed, the current sensing
circuit will cause the RANGER 250 LPG engine to go
to the high idle speed, the wire will begin to feed and
the welding process started. When welding 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 the RANGER 250 LPG
1. Shut the welder off.
2. Connect per instructions on the appropriate con-
nection diagram in Section F.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
B-1
B-1
OPERATION
SAFETY PRECAUTIONS
DESIGN FEATURES
Read and understand this entire section before
operating your RANGER 250 LPG.
ENGINE OPERATION
Before Starting the Engine:
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 safety precautions, detailed
engine starting, operating and maintenance
instructions and parts lists.
1. Be sure the machine is on a level surface.
2. Open top engine door and remove the engine oil
dipstick and wipe it with a clean cloth. Reinsert the
dipstick and check the level on the dipstick.
ELECTRIC SHOCK can kill.
•Do not touch electrically live parts
such as output terminals or internal
wiring.
3. Add oil (if necessary) to bring the level up to the full
mark. Do not overfill. Close engine door.
4. See Engine Owner’s Manual for specific oil recom-
mendations.
•Insulate yourself from the work and
ground.
WARNING
•Always wear dry insulating gloves.
------------------------------------------------------------------------
• The combustion of LPG fuel
does produce carbon monoxide.
Although the level of CO emis-
ENGINE EXHAUST can kill.
•Use in open, well ventilated areas or
vent exhaust outside
2
sion is lower than gasoline com-
bustion, the exhaust from the
Ranger 250 LPG can kill.
•Do not stack anything near the
engine.
------------------------------------------------------------------------
• Avoid breathing of vapor.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------
MOVING PARTS can injure.
•Do not operate with doors open or
guards off.
•Stop engine before servicing.
•Keep away from moving parts
------------------------------------------------------------------------
• Only qualified personnel should operate this
equipment.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged door
closed and the side panels in place as these pro-
vide maximum protection from moving parts and
insure proper cooling air flow.
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 uses state of
the art Chopper Technology (CT tm) for superior weld-
ing performance. The RANGER 250 LPG is not rec-
ommended for pipe thawing.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
B-2
B-2
OPERATION
14
1
2
13
12
11
10
3
9
8
7
6
5
4
WELDING CONTROLS:
CC-STICK mode: In this mode, 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
prevents 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.
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 pin or 14 pin Amphenol.
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 number from -10(soft) to +10(crisp)
increases the short circuit current which results in a more
forceful digging arc. Typically a forceful digging arc is pre-
ferred for root and hot passes. A softer arc is preferred for fill
and cap passes where weld puddle control and deposition
(“stacking” of iron) are key to fast travel speeds. It is recom-
mended that the ARC CONTROL be set initially at 0.
2. WELD MODE SELECTOR SWITCH:
(Provides four selectable welding modes)
CV-WIRE
DOWNHILL PIPE
CC-STICK
TOUCH START TIG
3. ARC CONTROL :
The ARC CONTROL WIRE/STICK dial is active in the
WIRE, STICK and DOWNHILL PIPE modes, and has
different functions in these modes. This control is not
active in the TIG mode.
CV-WIRE mode: In this mode, 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 induc-
tance control. The proper setting depends on the procedure
and operator preference. Start with a setting at 0.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
B-3
B-3
OPERATION
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.
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 start-
ing the engine, the engine will operate at full
speed for approximately 12 seconds and then go
to low idle speed.
5. GROUND STUD:
Provides a connection point for connecting the
machine case to earth ground for the safest grounding
procedure.
• When the electrode touches the work or power is
drawn for lights or tools (approximately 100 Watts
minimum), the engine accelerates and operates
at full speed.
• When welding ceases or the AC power load is
turned off, a fixed time delay of approximately 12
seconds starts. If the welding or AC power load is
not restarted before the end of the time delay, the
idler reduces the engine speed to low idle speed.
• The engine will automatically return to high idle
speed when there is welding load or AC power
load reapplied.
6. 14-PIN CONNECTOR:
For attaching wire feeder control cables to the
RANGER 250 LPG. Includes contactor closure circuit,
auto-sensing remote control circuit, and 120V and
42V power. The remote control circuit operates the
same as the 6-Pin connector.
7. 6-PIN CONNECTOR:
For attaching optional remote control equipment.
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 LPG automatically switches the OUTPUT control
from control at the welder to remote control .
14. ENGINE HOUR METER – Displays the total
time that the engine has been running. This meter is
useful for scheduling prescribed maintenance.
When using the TOUCH START TIG mode with a TIG
Module connected to the RANGER 250 LPG, the
OUTPUT control on the front of the RANGER 250
LPG is used to set the maximum current range of the
CURRENT CONTROL on the TIG Module.
STARTING AND STOPPING THE
ENGINE
1. Remove all plugs connected to the AC power
receptacles.
8. WELD TERMINALS CONTROL SWITCH:
In the WELD TERMINALS ON position, the output is
electrically hot all the time. In the REMOTELY CON-
TROLLED position, the output is controlled by a wire
feeder or amptrol device, and is electrically off until a
remote switch is depressed.
2. Set IDLER switch to AUTO.
3. Set the RUN/STOP switch to RUN.
4. Pull the choke to the full out position.
5. Press and hold the engine START button until the
engine starts.
9. WIRE FEEDER VOLTMETER SWITCH:
Matches the polarity of the wire feeder voltmeter to
the polarity of the electrode.
6. Release the engine START button when the engine
starts.
ENGINE CONTROLS:
7. Push the choke back in.
10. RUN/STOP SWITCH - RUN position ener-
gizes the engine prior to starting. STOP position stops
the engine. The oil pressure interlock switch prevents
battery drain if the switch is left in the RUN position
and the engine is not operating.
8. The engine will run at high idle speed for approxi-
mately 12 seconds and then go to low idle speed.
Allow the engine to warm up at low idle for several
minutes before applying a load and/or switching to
high idle. Allow a longer warm up time in cold
weather.
11. CHOKE - When pulled out, it closes the choke
valve on the engine carburetor for quick starting.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
B-4
B-4
OPERATION
Constant Current (CC-STICK) Welding
CAUTION
The CC-STICK position of the 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.
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.
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-
vents sticking of the electrode to the plate while weld-
ing. This can also increase spatter. It is recommended
that the ARC CONTROL be set to the minimum num-
ber without electrode sticking. Start with the dial set at
0.
STOPPING
Remove all welding and auxiliary power loads and
allow the engine to run at low idle speed for a few
minutes to cool the engine.
Stop the engine by placing the RUN-STOP in the
STOP position.
DOWNHILL PIPE Welding
Note: The engine will run for a breif moment (3 to 5
seconds) while the excess fuel is burned out of
the system.
This slope controlled setting is intended for "out-of-
position" and "down hill" pipe welding where the oper-
ator would like to control the current level by changing
the arc length. The output CONTROL dial adjusts the
full output range for pipe welding. The ARC CON-
TROL dial sets the short circuit current (arc-force) dur-
ing stick welding to adjust for a soft or more forceful
digging arc (crisp). Increasing the number from
-10(soft) to +10(crisp) increases the short circuit cur-
rent which results in a more forceful digging arc.
Typically a forceful digging arc is preferred for root
and hot passes. A softer arc is preferred for fill and
cap passes where weld puddle control and deposition
(“stacking” of iron) are key to fast travel speeds. This
can also increase spatter. It is recommended that the
ARC CONTROL be set to the minimum number with-
out electrode sticking. Start with the dial set at 0.
WELDER OPERATION
DUTY CYCLE
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.
DC Stick Welding
The RANGER 250 LPG can be used with a broad
range of DC stick electrodes.
The MODE switch provides two stick welding settings
as follows:
TYPICAL RANGER 250 LPG FUEL CONSUMPTION
Kohler CH20 S
20HP @ 3600 RPM
Lbs./Hr (Kg/hr)
Low Idle - No Load
2400 R.P.M.
3.42 (1.55)
4.46 (2.02)
7.22 (3.27)
7.23 (3.28)
High Idle - No Load
3700 R.P.M.
DC Weld Output
250 Amps @ 28 Volts
Auxiliary Power
8,000 Watts
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
B-5
B-5
OPERATION
• 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 is pressed.
TIG WELDING
The TOUCH START TIG setting of the MODE switch is for DC
TIG (Tungsten Inert Gas) welding. To initiate a weld, the CON-
TROL 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
tungsten contamination. Then, the tungsten is gently lifted off the
work in a rocking motion, which establishes the arc.
When using the TIG Module, the OUTPUT control on the
RANGER 250 LPG 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.
When in the TOUCH START TIG mode and when a Amptrol is
connected to the 6-Pin connector the OUTPUT dial is used to set
the maximum current range of the current control of the Amptrol.
WIRE WELDING-CV
Connect a wire feeder to the RANGER 250 LPG according to
the instructions in INSTALLATION INSTRUCTIONS Section.
The RANGER 250 LPG in the CV-WIRE mode, permits it to be
used with a broad range of flux cored wire (Innershield and
Outershield) electrodes and solid wires for MIG welding (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/pinch control. The
proper setting depends on the procedure and operator prefer-
ence. Start with the dial set at 0.
The ARC CONTROL is not active in the TIG mode. To STOP a
weld, simply pull the TIG torch away from the work. When the arc
voltage reaches approximately 30 Volts the arc will go out and
the machine will reset the current to the Touch Start level. To
reinitiate the arc, retouch the tungsten to the work and lift.
Alternatively, the weld can be stopped by releasing the Amptrol
or arc start switch.
The RANGER 250 LPG can be used in a wide variety of DC TIG
welding applications. In general the ‘Touch Start’ feature allows
contamination free starting without the use of a Hi-frequency unit.
If desired, the K930-2 TIG Module can be used with the
RANGER 250 LPG. The settings are for reference.
Listed below are some wires suitable for use on this machine:
• Innershield - NR-311, NS-3M, NR-207, NR-203 Ni 1%,
NR-212.
• Outershield - 0S-70, 0S-71M, 0S-71 ELITE.
• Solid wires for MIG welding - .035 (0.9 mm), and
.045 (1.1 mm), L-50 and L-56, .035 (0.9 mm) and
.045 (1.1 mm) Blue Max MIG 308 LS.
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.
Contact your local authorized Lincoln Electric Distributor or the
Lincoln Electric Company for specific wires used on certain
applications with this machine.
(1)
(2)
TYPICAL CURRENT RANGES
FOR TUNGSTEN ELECTRODES
Tungsten Electrode
Diameter in. (mm)
DCEN (-)
DCEP (+)
Approximate Argon Gas Flow
Flow Rate C.F.H. ( l /min.)
TIG TORCH
Nozzle Size (4), (5)
1%, 2% Thoriated
Tungsten
1%, 2% Thoriated Aluminum
Tungsten
Stainless Steel
.010
0.020
0.040
(.25)
(.50)
(1.0)
2-15
5-20
15-80
(3)
(3)
(3)
3-8
5-10
5-10
(2-4)
(3-5)
(3-5)
3-8
5-10
5-10
(2-4)
(3-5)
(3-5)
#4, #5, #6
1/16
(1.6)
70-150
10-20
5-10
(3-5)
9-13
(4-6)
#5, #6
3/32
1/8
(2.4)
(3.2)
150-250
250-400
15-30
25-40
13-17
15-23
(6-8)
(7-11)
11-15
11-15
(5-7)
(5-7)
#6, #7, #8
5/32
3/16
1/4
(4.0)
(4.8)
(6.4)
400-500
500-750
750-1000
40-55
55-80
80-125
21-25
23-27
28-32
(10-12)
(11-13)
(13-15)
13-17
18-22
23-27
(6-8)
(8-10)
(11-13)
#8, #10
(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
2% Thoriated
EWTh-1
EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.
(3) DCEP is not commonly used in these sizes.
(4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:
# 4 = 1/4 in.
# 5 = 5/16 in.
# 6 = 3/8 in.
# 7 = 7/16 in.
# 8 = _ in.
(6 mm)
(8 mm)
(10 mm)
(11 mm)
(12.5 mm)
(16 mm)
#10 = 5/8 in.
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures
and high duty cycles.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
B-6
B-6
OPERATION
The auxiliary power capacity is 9,000 Watts Peak,
8000 Watts Continuous of 60 Hz, single phase power.
The auxiliary power capacity rating in watts is equiva-
lent to volt-amperes at unity power factor. The max
permissible current of the 240 VAC output is 33 Amps.
The 240 VAC output can be split to provide two sepa-
rate 120 VAC outputs with a max permissible current
of 33 Amps per output to two separate 120 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.
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 Current Range (DC, electrode positive)
1/8" (3.2mm)
30-60 Amps
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.
5/32" (4.0mm)
90-150 Amps
200-250 Amps
3/16" (4.0mm)
AUXILIARY POWER:
Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
regardless of the welding control settings providing no
welding current is being drawn.
NOTE: The 240 V receptacle has two circuits, each of
which measure 120 V to neutral but are of opposite
polarities and cannot be paralleled.
The auxiliary power of the RANGER 250 LPG con-
sists of two 20 Amp-120 VAC (5-20R) GFCI duplex
receptacles and one 50 Amp 120/240 VAC (14-50R)
receptacle. The 240 VAC receptacle can be split for
single phase 120 VAC operation. If a GFCI receptacle
is tripped, See the MAINTENANCE section for
detailed information on testing and resetting the GFCI
receptacle.
Simultaneous Welding and Auxiliary Power Loads
The above auxiliary power ratings are with no welding
load. Simultaneous welding and power loads are
specified in the following table. The permissible cur-
rents shown assume that current is being drawn from
either the 120 VAC or 240 VAC supply (not both at the
same time).
RANGER 250 LPG Simultaneous Welding and Power Loads
Permissible Auxiliary
Current in -Amps
Permissible Power-Watts
(Unity Power Factor)
Welding
Output-Amps
@120 VAC *
@ 240 VAC
66**
48**
38**
24
33
24
19
12
4
8000
5300
4000
2700
750
0
100
150
200
250
8
* Each duplex receptacle is limited to 20 amps.
** Not to exceed 35 A per 120 VAC branch circuit when splitting the 240 VAC output.
RANGER 250 LPG Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
12 AWG 10 AWG 8 AWG 6 AWG
Current Voltage Load
(Amps) Volts (Watts)
14 AWG
4 AWG
15
20
15
20
33
120
120
240
240
240
1800
2400
3600
4800
8000
30
(9)
40
(12)
(9)
75
(23)
(15)
(46)
(30)
(18)
125
88
(38)
(27)
(69)
(53)
(30)
175
(53)
(42)
(107)
(84)
(53)
300
(91)
(69)
30
75
60
50
150
100
60
138
350
275
175
225
600
450
250
60
(18)
(23)
(18)
225
175
100
(183)
(137)
(76)
Conductor size is based on maximum 2.0% voltage drop.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
C-1
C-1
ACCESSORIES
K802-N POWER PLUG KIT
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:
Provides four 120 volt plugs rated at 20 amps each
and one dual voltage, full KVA plug rated at 120/240
volts, 50 amps.
K802-R POWER PLUG KIT
Provides four 120 volt plugs rated at 15 amps each
and one dual voltage, full KVA plug rated at 120/240
volts, 50 amps.
K957-1 Trailer
K958-1 Ball Hitch
T12153-9 50 AMP, 120/240V POWER PLUG
K958-2 Lunette Eye Hitch
K959-2 Fender & Light Kit
K965-1 Cable Storage Rack
K1816-1 FULL KVA ADAPTER KIT
Plugs into the 120/240V NEMA 14-50R receptacle on
the case front (which accepts 4-prong plugs) and con-
verts it to a NEMA 6-50R receptacle, (which accepts
3-prong plugs.) For connection of Lincoln equipment
with NEMA 6-50r plug.
K1737-1 FOUR WHEEL ALL-TERRAIN UNDER-
CARRIAGE - For moving by hand at construction
sites. Heavy duty puncture resistant pneumatic tires.
TIG Welding
K1770-1 UNDERCARRIAGE (FACTORY)
For moving by hand on a smooth surface. Heavy duty
puncture resistant pneumatic tires and front caster.
One or two gas cylinders can be mounted on the rear
of the undercarriage with the installation of K1745-1
Cylinder Holder(s).
K1783-9 TIG Torch PTA-26V (25ft.)
K963-3 Hand Amptrol
K870 Foot Amptrol
KP509 Magnum Parts Kit
Spool Gun
K1739-1 CABLE CARRIER KIT - For use on K1737-1
and K1770-1 Undercarriages.
K1849-1 Adapter Module
K1745-1 GAS CYLINDER HOLDER - Holds welding
gas cylinder or LPG Tank. (For products with LPG
Tank). Can use either one or two holders with K1770-
1 under carrage.
K487-25 Magnum Spool Gun
K488 Magnum Control Module
K691-10 Input Cable
K2361-1 LPG TANK HOLDER KIT- Mounts to K1745-1
gas cylinder holder to secure LPG tank.
K886-2 CANVAS COVER - Protects 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 control provides same dial range as
the output control on the welder. Has a convenient 6 pin
plug for easy connection to the welder.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
D-1
D-1
MAINTENANCE
SAFETY PRECAUTIONS
KOHLER ENGINE
FREQUENCY
Daily or Before
Starting Engine
MAINTENANCE REQUIRED
WARNING
• Check oil level.
• Check air cleaner for dirty, loose, or dam-
aged parts.
• Check air intake and cooling areas, clean
as necessary.
• 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 to
perform maintenance and replace them when
the maintenance requiring their removal is
complete. If guards are missing from the
machine, obtain replacements from a Lincoln
Distributor. (See Operating Manual Parts List.)
First Oil Change
5 Hours
Every 25 Hours
Every 100 Hours
• Service air pre-cleaner..
(1)
• Change engine oil.
(1)
• Clean or replace air filter element.
(1)
• Replace oil filter.
Every 200 Hours
Every 1000 Hours
• Check spark plug and gap
Read the Safety Precautions in the front of this
manual and in the Engine Owner’s Manual before
working on this machine.
• Check fuel lines and clamps.
(1) Service more frequently when used in dusty areas and/or at high ambient
temperatures.
Keep all equipment safety guards, covers, and
devices in position and in good repair. Keep
hands, hair, clothing, and tools 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.
ENGINE MAINTENANCE COMPONENTS
ITEM
MAKE AND PART NUMBER
KOHLER CH730S ENGINE
Oil Filter
Kohler 12 050 01, Fram PH8172
Kohler 47 083 03, Fram CA79
Kohler 24 083 10
Air Filter Element
Air Filter Pre-Cleaner
Spark Plug
Champion RC12YC (.030" Gap)
BCI Group 58 (435 CCA)
Battery
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
D-2
D-2
MAINTENANCE
ENGINE OIL CHANGE
Drain the oil while the engine is warm to assure rapid
and complete draining.
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.
• 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 the oil into a suitable contain-
er.
AIR CLEANER SERVICE
A dirty air cleaner will restrict air flow to the carbure-
tor. To prevent carburetor malfunction, service the air
cleaner regularly. Service more frequently when
operating the engine in extremely dusty areas.
• Close the drain valve by pushing in and twisting
clockwise. Replace the yellow cap.
WARNING
• Never use gasoline or low flash point solvents
for cleaning the air cleaner element. A fire or
explosion could result.
• Refill to the upper limit mark on the dipstick with the
recommended oil. Tighten the oil filler cap securely.
ENGINE OIL REFILL CAPACITIES
Without oil filter replacement:
CAUTION
•1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler
• Never run the engine without the air cleaner.
Rapid engine wear will result from contaminants,
such as dust and dirt being drawn into the
engine.
With oil filter replacement:
•2.0 US qt. (1.7 Imp qt., 1.9 liter)-Kohler
-----------------------------------------------------------------------
Use 4-stroke motor oil that meets or exceeds the
requirements for API service classification SG or SH.
Always check the API SERVICE label on the oil con-
tainer to be sure it includes the letters SG or SH.
SAE 10W-30 is recommended for general, all-temper-
ature use, -5 F to 104 F (-20 C to 40 C).
AIR PRE-CLEANER SERVICE
1. Loosen the cover retaining knob and remove the
cover.
2. Remove the pre-cleaner from the paper element.
See Engine Owner’s Manual for more specific infor-
mation on oil viscosity recommendations.
Wash your hands with soap and water after handling
used oil.
Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you
take it in a sealed container to your local service sta-
tion or recycling center for reclamation. Do not throw it
in the trash, pour it on the ground or down a drain.
3. Wash the pre-cleaner in warm water with detergent.
Rinse the pre-cleaner thoroughly until all traces of
detergent are eliminated. Squeeze out excess
water (do not wring). Allow the pre-cleaner to air
dry.
4. Saturate the pre-cleaner with new engine oil.
Squeeze out all excess oil.
5. Reinstall the pre-cleaner over the paper element.
OIL FILTER CHANGE
1. Drain the engine oil.
6. Reinstall the air cleaner cover. Secure cover with
the cover retaining knob.
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 the specified amount of
the recommended oil. Reinstall the oil filler cap.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
D-3
D-3
MAINTENANCE
5. Measure the plug gap with a feeler gauge. Correct
as necessary by bending the side electrode.
AIR FILTER PAPER ELEMENT
1. Loosen the cover retaining knob and remove the
cover.
6. Check that the spark plug washer is in good condi-
tion and thread the spark plug in by hand to prevent
cross-threading.
2. Remove the pre-cleaner from the paper element.
3. Remove the element cover nut, element cover, and
paper element.
7. After the spark plug is seated, tighten with a spark
plug wrench to compress the washer. (See proper
spark plug torque which is specified below).
4. Do not wash the paper element or use pressurized
air, as this will damage the element. Replace a
dirty, bent, or damaged element with a new ele-
ment. Handle new elements carefully; do not use if
the sealing surfaces are bent or damaged.
Spark Plug Gap: .030 in. (0.76 mm)-Kohler Engine
5.When servicing the air cleaner, check the air cleaner
base. Make sure it is secured and not bent or dam-
aged. Also check the element cover for damaged or
improper fit. Replace all damaged air cleaner com-
ponents.
Spark Plug Torque: 20 ft. Lb. (27 N-m)-Kohler Engine
CAUTION
NOTE: Before air cleaner is reassembled make sure
rubber seal is in position around stud. Inspect, making
sure it is not damaged and seals with the element
cover.
The spark plug must be securely tightened. An
improperly tightened spark plug can become very
hot and may cause engine damage.
Use only the recommended spark plug or equiva-
lent. A spark plug which has an improper heat
range may cause engine damage.
6. Reinstall the paper element, pre-cleaner, element
cover, element cover nut, and air cleaner cover.
Secure cover with the cover retaining knob.
------------------------------------------------------------------------
SPARK PLUG
To ensure proper engine operation, the spark plug
must be properly gapped and free of deposits.
WARNING
NOTE: Before removing 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 plug.
4. Visually inspect the spark plug. Discard them if the
insulator is cracked or chipped. Clean the spark
plug with a wire brush if it is to be reused.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
D-4
D-4
MAINTENANCE
ENGINE ADJUSTMENT
CLEANING THE BATTERY
Keep the battery 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 (0.9461liter) of water. Be
sure the battery vent plugs (if equipped) are tight so
that none of the solution enters the cells.
OVERSPEED IS HAZARDOUS
The maximum allowable high idle speed for this
machine is 3750 RPM, no load. Do NOT tamper with
governor components or setting or make any other
adjustments to increase the maximum speed. Severe
personal injury and damage to the machine can result
if operated at speeds above maximum.
After cleaning, flush the outside of the battery, the bat-
tery compartment, and surrounding areas with clear
water. Coat the battery terminals lightly with petroleum
jelly or a non-conductive grease to retard corrosion.
Keep the battery clean and dry. Moisture accumula-
tion on the battery can lead to more rapid discharge
and early battery failure.
Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.
BATTERY 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 terminals.
CHECKING THE ELECTROLYTE LEVEL
If battery cells are low, fill them to the neck of the filler
hole with distilled water and recharge. If one cell is
low, check for leaks.
WARNING
CHARGING THE BATTERY
GASES FROM BATTERY can explode.
When you charge, jump, replace, or otherwise con-
nect battery cables to the battery, be sure the polarity
is correct. Improper polarity can damage the charging
circuit. The RANGER 250 LPG positive (+) battery
terminal has a red terminal cover.
•
Keep sparks, flame and cigarettes
away from battery.
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and con-
nect to new battery last.
If you need to charge the battery with an external
charger, disconnect the negative cable first, then the
positive cable before you attach the charger leads.
After the battery is charged, reconnect the positive
battery cable first and the negative cable last. Failure
to do so can result in damage to the internal charger
components.
• CONNECTING A BATTERY CHARGER —
remove battery from welder by disconnecting
negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
• USING A BOOSTER — connect positive lead to
battery first then connect negative lead to neg-
ative battery lead at engine foot.
Follow the instructions of the battery charger manu-
facturer for proper charger settings and charging time.
BATTERY ACID can burn eyes and skin.
SERVICING OPTIONAL SPARK
ARRESTER
• Wear gloves and eye protection
and be careful when working near
battery.
WARNING
• Follow instructions printed on bat-
tery.
Clean every 100 hours.
------------------------------------------------------------------------
MUFFLER MAY BE HOT
• ALLOW ENGINE TO COOL BEFORE INSTALLING
THE SPARK ARRESTER!
• DO NOT OPERATE ENGINE WHILE INSTALLING
THE SPARK ARRESTER!
------------------------------------------------------------------------------------------
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
D-5
D-5
GFCI RECEPTACLE TESTING AND RESET-
MAINTENANCE
WELDER / GENERATOR
MAINTENANCE
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:
STORAGE: Store the RANGER 250 LPG in clean,
dry protected 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.
• If the receptacle has tripped, first carefully remove
any load and check it for damage.
• If the equipment has been shut down, it must be
restarted.
BRUSH REMOVAL AND REPLACEMENT: It’s nor- • The equipment needs to be operating at high idle
mal for the brushes and slip rings to wear and darken
slightly. Inspect the brushes when a generator over-
haul is necessary.
speed and any necessary adjustments made on the
control panel so that the equipment is providing at
least 80 volts to the receptacle input terminals.
• The circuit breaker for this receptacle must not be
tripped. Reset if necessary.
CAUTION
• Push the "Reset" button located on the GFCI recep-
tacle. This will assure normal GFCI operation.
• Do not attempt to polish slip rings while the • Plug a night-light (with an "ON/OFF" switch) or other
engine is running.
product (such as a lamp) into the GFCI receptacle
and turn the product "ON".
• Push the "Test" button located on the GFCI recepta-
cle. The night-light or other product should go
"OFF".
• Push the "Reset" button, again. The light or other
product should go "ON" again.
WARNING
• 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
warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and pre-
cautions.
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
Download from Www.Somanuals.com. All Manuals Search And Download.
E-1
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
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.
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.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
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.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Major Physical or Electrical 1. If all recommended possible
Damage is Evident.
areas of misadjustment have
been checked and the problem
persists,Contact your local
Lincoln Authorized Field
Service Facility.
Engine will not "crank".
1. Battery is low.
2. Loose battery cable connections.
3. Faulty engine starter motor.
4. “Battery Circuit” circuit breaker is
tripped.
Engine will "crank" but not start.
1. LPG fuel cylinder empty.
2. Faulty fuel solenoid or faulty PC
board or ignition system.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
Engine shuts down shortly after 1. Low oil level.
starting.
2. Faulty oil pressure switch or
other engine component.
3. Open rotor circuit.
Battery does not stay charged.
1. Faulty battery.
2. Loose connections at battery or
alternator.
3. Faulty engine alternator or
charger module.
CAUTION
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.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Engine will not idle down to low 1. Idler switch in High idle position.
speed.
2. External load on welder or auxil-
iary power.
3. Faulty PC board or idler sole-
noid.
Engine will not go to high idle when 1. Poor work lead connection to
attempting to weld.
work.
2. "Contactor" switch is in wrong
position.
3. Faulty PC board. Low idle speed
set to low.
Engine will not go to high idle when 1. Auxiliary power load is less than
using auxiliary power.
100 watts.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
2. Faulty PC board.
Engine does not develop full power. 1. Air filter clogged.
2. Fouled spark plugs.
3. Valves out of adjustment.
CAUTION
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.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
No welding power output.
1. Poor work lead connection to
work.
2. "Weld Terminals" switch in
wrong position.
3. Faulty PC board or welder alter-
nator.
Welder has output but no control.
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.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service
Facility.
Wire feeder does not work when 1. Wire Feeder Power circuit
control cable is connected to 14-
pin connector.
breaker open.
2. Faulty control cable.
3. Faulty wire feeder.
No auxiliary power.
1. Open circuit breakers.
2. Faulty connections to auxiliary
receptacles.
3. GFCI tripped.
4. Faulty PC board or welder alter-
nator.
CAUTION
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.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
The welding arc is “cold.” The
welding arc is not 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-
nections.
4. The welding cables may be too
long or coiled, causing an exces-
sive voltage drop.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
CAUTION
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.
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
F-1
F-1
DIAGRAMS
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
F-2
F-2
DIAGRAMS
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
F-3
F-3
DIAGRAMS
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
F-4
F-4
DIAGRAMS
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
F-5
F-5
DIAGRAMS
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
F-6
F-6
DIAGRAMS
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
F-7
F-7
DIAGRAMS
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
F-8
F-8
DIAGRAMS
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
F-9
F-9
DIAGRAMS
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
F-10
F-10
DIAGRAMS
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
F-11
F-11
DIAGRAMS
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
F-12
F-12
DIMENSION PRINT
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
NOTES
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
NOTES
RANGER 250 LPG
Download from Www.Somanuals.com. All Manuals Search And Download.
● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● Keep flammable materials away.
● Wear eye, ear and body protection.
WARNING
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Download from Www.Somanuals.com. All Manuals Search And Download.
● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
Spanish
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux
tien.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
● Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
Download from Www.Somanuals.com. All Manuals Search And Download.
• World's Leader in Welding and Cutting Products •
• 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
Download from Www.Somanuals.com. All Manuals Search And Download.
|