Lincoln Electric RANGER 250 Operator's Manual
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Lincoln Electric RANGER 250 Operator's Manual

Lincoln electric welder user manual
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RETURN TO MAIN MENU
IM741-A
Ranger 250
April, 2003
10795; 10854; 10953; 10954
For use with machines having Code Numbers:
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.
OPERATOR'S MANUAL
Copyright © 2003 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

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  • Page 1 RETURN TO MAIN MENU IM741-A Ranger 250 April, 2003 10795; 10854; 10953; 10954 For use with machines having Code Numbers: 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 ...

  • Page 2: California Proposition 65 Warnings

    351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    ELECTRIC SHOCK can 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.
  • Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent 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.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 The code number is especially important when identifying the correct replacement parts. - 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.

  • Page 7: Table Of Contents

    Welding Terminals ...A-5 Welding Output Cables ...A-5 Cable Installation...A-5 Auxiliary Power Receptacles and Plugs ...A-6 Standby Power Connections ...A-6 Premises Wiring ...A-7 Connection of Lincoln Electric Wire Feeders ...A-8 ________________________________________________________________________________ Operation...Section B Safety Precautions ...B-1 General Description...B-1 Design Features ...B-1 Engine Operation ...B-1...
  • Page 8 Spark Plug ...D-3 Spark Plug Service ...D-3 Fuel Filter ...D-4 Engine Adjustment ...D-4 Battery Maintenance ...D-4 Option Spark Arrestor ...D-4,D-5 Welder / Generator Maintenance ...D-5 Storage ...D-5 Cleaning...D-5 Brush Removal and Replacement ...D-5 ________________________________________________________________________ Troubleshooting ...Section E How to Use Troubleshooting Guide...E-1 Troubleshooting Guide ...E-2...

  • Page 9: Installation

    TECHNICAL SPECIFICATIONS - Ranger 250 ( K1725-2, K1725-4) Make/Model Description Horsepower Operating Displacement cu. in.(cu. cm) @ 3600 RPM K1725-2 Kohler CH20 20 HP 2 Cylinder 4 Cycle Air Cooled Gasoline K1725-4 Engine Onan P220 20.5 HP RATED OUTPUT @ 104°F(40C°) - WELDER Welding Output CC STICK &...

  • Page 10: Machine Specifications

    MACHINE SPECIFICATIONS - Ranger 250 (K1725-2, K1725-4) RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER (2) 120VAC Duplex (5-20R) (1) 120/240VAC Dual Voltage Full KVA (14-50R) INSTALLATION Two 20AMP for Two Duplex Receptacle Two 40AMP for Dual Voltage RANGER 250 OTHER CIRCUIT BREAKERS...

  • Page 11: Safety Precautions

    12 gallons. INSTALLATION LIFTING The RANGER 250 weighs approximately 575 lbs. with a full tank of gasoline. A lift bail is mounted to the machine and should always be used when lifting the machine.

  • Page 12: Pre-Operation Engine Service

    REMOTE CONTROL The Ranger 250 is equipped with a 6 pin and a 14 pin Amphenol connector. The 6 pin connector is for con- necting the K857 or K857-1 Remote Control (optional) or for TIG welding, the K870 foot Amptrol or the K812 hand Amptrol.

  • Page 13: Electrical Connections

    WELDING TERMINALS The Ranger 250 is equipped with a toggle switch for selecting "hot" welding terminal when in the "WELD TERMINALS ON" position or "cold" welding terminal when in the "REMOTELY CONTROLLED"...

  • Page 14: Standby Power Connections

    2. Take necessary steps to assure load is limited to the capacity of the RANGER 250 by installing a 40 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 35 amperes.

  • Page 15: Premises Wiring

    CONNECTION OF RANGER 250 TO PREMISES WIRING 240 VOLT POWER 240 Volt 60 Hz. COMPANY 3-Wire Service METER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. 50 AMP, 120/240 VOLT PLUG...

  • Page 16: Connection Of Lincoln Electric Wire Feeders

    When the gun trigger is closed, the current sensing cir- cuit will cause the Ranger 250 engine to go to the high idle speed, the wire will begin to feed and the welding process can be started. When welding is...

  • Page 17: Operation

    GENERAL DESCRIPTION The Ranger 250 is a gasoline engine powered DC multi-process welding power source and 120 / 240 volt AC power generator. The engine drives a genera-...

  • Page 18: Welding Controls

    The proper setting depends on the procedure and operator preference. Start with a setting at 0. 4. WELD OUTPUT TERMINALS WITH FLANGE NUT: Provides a connection point for the electrode and work cables. RANGER 250...

  • Page 19: Engine Controls

    When using the TOUCH START TIG mode with a TIG Module connected to the Ranger 250, the OUTPUT control on the front of the Ranger 250 is used to set the maximum current range of the CURRENT CON- TROL on the TIG Module.

  • Page 20: Stopping

    Auxiliary Power 8,500 Watts OPERATION WELDER OPERATION DC Stick Welding The Ranger 250 can be used with a broad range of DC stick electrodes. The MODE switch provides two stick welding settings as follows: Constant Current (CC-STICK) Welding The CC-STICK position of the MODE switch is designed for horizontal and vertical-up welding with all types of electrodes, especially low hydrogen.

  • Page 21: Tig Welding

    Amptrol or arc start switch. The Ranger 250 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.

  • Page 22: Arc Gouging

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

  • Page 23: Accessories

    K857 25 ft (7.5m) or K857-1 100 ft. (30.4m) REMOTE CON- TROL - Portable control provides same dial range as the output control on the welder. Has a convenient 6 pin plug for easy connection to the welder. ACCESSORIES...

  • Page 24: Maintenance

    Kohler 4708303, Fram CA79 Kohler 2408302 Kohler 2405002, Fram G Champion RC12YC (.030" Gap) BCI Group 58 (435 CCA) RANGER 250 MAINTENANCE REQUIRED • Fill fuel tank. • Check oil level. • Check air cleaner for dirty, loose, or dam- aged parts.

  • Page 25: Engine Oil Change

    (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. 6. Reinstall the air cleaner cover. Secure cover with the cover retaining knob. RANGER 250 WARNING CAUTION...

  • Page 26: Air Filter Paper Element

    Use only the recommended spark plug or equiva- lent. A spark plug which has an improper heat range may cause engine damage. ------------------------------------------------------------------------ RANGER 250 11 ft. Lb. (14 N-m)-Onan Engine’s CAUTION...

  • Page 27: Fuel Filter

    Improper polarity can damage the charging circuit. The RANGER 250 positive (+) battery terminal has a red terminal cover. 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.

  • Page 28: Welder / Generator Maintenance

    WELDER / GENERATOR MAINTENANCE STORAGE: Store the RANGER 250 in clean, dry pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air. Do this at least once a week in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT: It’s nor- mal for the brushes and slip rings to wear and darken slightly.

  • Page 29: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 30 1. Faulty battery. 2. Loose connections at battery or alternator. 3. Faulty engine alternator or charger module. CAUTION RANGER 250 RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln...
  • Page 31 2. Faulty PC board. 1. Fuel filter clogged. 2. Air filter clogged. 3. Fouled spark plugs. 4. Valves out of adjustment. CAUTION RANGER 250 RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.
  • Page 32 2. Faulty connections to auxiliary receptacles. 3. GFCI tripped (if installed). 4. Faulty PC board or welder alter- nator. CAUTION RANGER 250 RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists,...
  • Page 33 4. The welding cables may be too long or coiled, causing an exces- sive voltage drop. CAUTION RANGER 250 RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.
  • Page 34 DIAGRAMS RANGER 250...
  • Page 35 DIAGRAMS RANGER 250...
  • Page 36 DIAGRAMS RANGER 250...
  • Page 37 DIAGRAMS RANGER 250...
  • Page 38 DIAGRAMS RANGER 250...
  • Page 39 DIAGRAMS RANGER 250...
  • Page 40 DIAGRAMS RANGER 250...
  • Page 41 DIAGRAMS RANGER 250...
  • Page 42 DIAGRAMS RANGER 250...
  • Page 43 F-10 F-10 DIAGRAMS RANGER 250...
  • Page 44 F-11 F-11 DIAGRAMS RANGER 250...
  • Page 45 F-12 F-12 DIAGRAMS RANGER 250...
  • Page 46 F-13 DIAGRAMS BLACK WHITE WHITE RANGER 250 F-13 BLACK...
  • Page 47 F-14 F-14 DIAGRAMS RANGER 250...
  • Page 48 NOTES RANGER 250...
  • Page 49 NOTES RANGER 250...
  • Page 50 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● German ● WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 51 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 52 • 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...

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