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IM919
®
March, 2008
Ranger 250
For use with machines having Code Numbers: 11401, 11421, 11422
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.
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté specifiques qui parraissent dans ce la masse. Un court-circuit accidental peut provoquer un manuel aussi bien que les précautions de sûreté générales suiv- échauffement et un risque dʼinc
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Linco
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vi vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Machine Specifications ........................................................................................................A-2 Safety Precautions. ..............................................
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vii vii TABLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ......................................................................................D-1 Kohler / Robin-Subaru Engine Maintenance Components....................................D-1 Kohler Engine .................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Ranger® 250 ( K1725-10, K1725-11, K1725-12) INPUT - GASOLINE 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 K1725-10, -11 41.1 (674) Fuel: 12gal.(45.4L) High Kohler CH23S 23 HP 3.15x 2.64 (80x67) Oil: 2.0qts.(1.9L) 2 Cylinder 3700RPM OHV Push Button 4 Cycle Air Cooled Full Load Starter 3500RPM Gasol
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A-2 A-2 INSTALLATION MACHINE SPECIFICATIONS - Ranger® 250 ( K1725-10, K1725-11, K1725-12) RECEPTACLES AND CIRCUIT BREAKERS RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS (2) 120VAC Duplex (5-20R) Two 20AMP for Two Duplex Receptacle 20AMP for Battery Charging Circuit (1) 120/240VAC Dual Voltage One 50AMP for Dual Voltage (2-Pole) 15AMP for 42V Wire Feeder Power Full KVA (14-50R) RANGER® 250
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A-3 A-3 INSTALLATION LIFTING SAFETY PRECAUTIONS The RANGER® 250 weighs approximately 575 lbs. with a full tank of gasoline. A lift bail is mounted to the WARNING machine and should always be used when lifting the Do not attempt to use this equipment until you machine. have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes ADDITIONAL SAFETY PRECAUTIONS important safety precautions, detailed engine starting, operating and maintenance instructions, and parts
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A-4 A-4 INSTALLATION TOWING WARNING The recommended trailer for use with this equipment (1) • Stop engine while fueling. for road, in-plant and yard towing by a vehicle is Lincolnʼs K957-1. If the user adapts a non-Lincoln • Do not smoke when fueling. trailer, he must assume responsibility that the method • Keep sparks and flame away of attachment and usage does not result in a safety from tank. hazard nor damage the welding equipment. Some of • Do not leave unattended while the factors to be
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A-5 A-5 INSTALLATION The RANGER® 250 is shipped with the negative battery The 14-pin connector is used to directly connect a cable disconnected. Make certain that the RUN-STOP wire feeder or TIG Module (K930-2) control cable. In switch is in the STOP position. Remove the two screws the CV-WIRE mode, the Ranger® 250 auto-sensing from the rear battery tray using a screwdriver or a 3/8" circuit automatically makes the Ranger® 250 Output socket. Attach the negative battery cable to the negative
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A-6 A-6 INSTALLATION The auxiliary power capacity is 10,500 Watts Peak, 9500 WELDING TERMINALS Watts Continuous of 60 Hz, single phase power. The auxiliary The Ranger® 250 is equipped with a toggle switch for select- power capacity rating in watts is equivalent to volt-amperes at ing "hot" welding terminal when in the "WELD TERMINALS unity power factor. The max permissible current of the 240 ON" position or "cold" welding terminal when in the "REMOTE- VAC output is 40 Amps. The 240 VAC output
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A-7 A-7 INSTALLATION CONNECTION OF RANGER® 250 TO PREMISES 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 120 VOLT 60 Hz. COMPANY 3-Wire 120 VOLT Service 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 GROUND OVERCURRENT 50AMP PROTECTION 240 VOLT DOUBLE POLE 50 AMP, 120/240 CIRCUIT VOLT PLUG 240 VOLT BREAKER NEMA TYPE 14-50 GND N 50 AMP, 120/240 VOLT NOTE: No. 6 COPPER CONDU
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A-8 A-8 INSTALLATION • Control Cable Model: CONNECTION OF LINCOLN ELEC- TRIC WIRE FEEDERS Connect Control Cable between Engine Welder and Feeder. Connection of LN-7 or LN-8 to the Ranger® 250 Set the "WELD TERMINALS" switch to "REMOTELY 1. Shut the welder off. CONTROLLED" 2. Connect the LN-7 or LN-8 per instructions on the • Set the MODE switch to the "CV-WIRE " position. appropriate connection diagram in Section F • Set the "WIRE FEEDER VOLTMETER" switch to 3. Set the "WIRE FEEDER VOLTMETER"
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A-9 A-9 INSTALLATION 7. Set the "IDLE" switch to the "AUTO" position. When not welding, the Ranger® 250 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 sens- ing circuit will cause the Ranger® 250 engine to go to the high idle speed, the wire will begin to feed and the welding process started. When weld- ing is stopped, the engine will rever
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B-1 B-1 OPERATION SAFETY PRECAUTIONS DESIGN FEATURES Read and understand this entire section before ENGINE OPERATION operating your Ranger® 250. Before Starting the Engine: Do not attempt to use this equipment until you have thoroughly read all operating and mainte- 1. Be sure the machine is on a level surface. nance manuals supplied with your machine. They include important safety precautions, detailed 2. Open top engine door and remove the engine oil engine starting, operating and mainten
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B-2 B-2 OPERATION 15 1 14 13 12 2 11 10 3 9 8 7 6 4 5 CC-STICK mode: In this mode, the ARC CONTROL dial WELDING CONTROLS: sets the short circuit current (arc-force) during stick weld- 1. OUTPUT CONTROL: The CONTROL dial ing to adjust for a soft or crisp arc. Increasing the number provides continuous control of the welding current or from -10(soft) to +10(crisp) increases the short circuit cur- welding voltage depending on the selected welding rent and prevents sticking of the electrode to the pl
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B-3 B-3 OPERATION 13. IDLER SWITCH- Has two positions as follows: 4. WELD OUTPUT TERMINALS WITH 1) In the HIGH position, the engine runs at the high FLANGE NUT: idle speed controlled by the engine governor. Provides a connection point for the electrode and 2) In the AUTO position, the idler operates as follows: work cables. Output stud covers provided on code 11270 and above. • When switched from HIGH to AUTO or after starting the engine, the engine will operate at full speed for 5. GROUND STUD
