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For use with machines having Code Numbers:
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
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.
• 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
Ranger
®
11401, 11421, 11422
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
250
Copyright © Lincoln Global Inc.
IM919
March, 2008
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Table of Contents
Related Manuals for Lincoln Ranger 250
Summary of Contents for Lincoln Ranger 250
- Page 1 March, 2008 11401, 11421, 11422 For use with machines having Code Numbers: This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci cations and availability of optional features may have changed. Safety Depends on You...
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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
SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 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”... - Page 4 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.
- Page 5 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...
- Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 7: Table Of Contents
Welding Terminals ......................A-6 Welding Output Cables ....................A-6 Cable Installation......................A-6 Auxiliary Power Receptacles and Plugs ................A-6 Standby Power Connections ....................A-6 Premises Wiring ........................A-7 Connection of Lincoln Electric Wire Feeders..............A-8, A-9 ________________________________________________________________________________ Operation.........................Section B Safety Precautions ......................B-1 General Description......................B-1 Design Features ........................B-1 Engine Operation ......................B-1... - Page 8 TABLE OF CONTENTS Maintenance......................Section D Safety Precautions ....................D-1 Routine Maintenance ..................D-1 Kohler / Robin-Subaru Engine Maintenance Components........D-1 Kohler Engine .......................D-1 Subaru Robin Engine ....................D-1 Engine Oil Change..................D-2 Engine Oil Refill Capacities (Kohler / Subaru Robin)........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...
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Page 9: Installation
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... -
Page 10: Machine Specifications
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) -
Page 11: Safety Precautions
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. -
Page 12: Towing
• Do not leave unattended while the factors to be considered are as follows: fueling. • Wipe up spilled fuel and allow 1. Design capacity of trailer vs. weight of Lincoln GASOLINE fumes to clear before starting equipment and likely additional attachments. -
Page 13: Muffler Outlet Pipe
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®... -
Page 14: Welding Terminals
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"... - Page 15 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 LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.
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Page 16: Connection Of Lincoln Electric Wire Feeders
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 CONTROLLED" 1. Shut the welder off. - Page 17 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.
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Page 18: Operation
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. -
Page 19: Welding Controls
OPERATION 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 plate... -
Page 20: Engine Controls
OPERATION 13. IDLER SWITCH 4. WELD OUTPUT TERMINALS WITH - Has two positions as follows: 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. -
Page 21: Duty Cycle
OPERATION CAUTION DC STICK WELDING Operating the starter motor for more than 5 seconds The Ranger® 250 can be used with a broad range of DC can damage the motor. If the engine fails to start, stick electrodes. release the switch and wait 10 seconds before opera- The MODE switch provides two stick welding settings as tion the starter again. -
Page 22: Tig Welding
Contact your local authorized Lincoln Electric Distributor or • Set the "WELDING TERMINALS" switch to the "REMOTE- the Lincoln Electric Company for specific wires used on cer- LY CONTROLLED" position. This will keep the "Solid tain applications with this machine. -
Page 23: Arc Gouging
OPERATION ARC GOUGING The auxiliary power capacity is 10,500 Watts Peak, 9500 Watts Continuous of 60 Hz, single phase power. The Ranger® 250 can be used for limited arc gouging. The auxiliary power capacity rating in watts is equiva- For optimal performance, set the MODE switch to CC- lent to volt-amperes at unity power factor. -
Page 24: Accessories
ACCESSORIES RECOMMENDED OPTIONAL K1690-1 GFCI RECEPTACLE KIT - Includes one UL approved 120V ground fault circuit interrupter duplex EQUIPMENT type receptacle with cover and installation instruc- K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR tions. Replaces the factory installed 120V duplex SMALL WELDERS - For road, off-road and in-plant receptacle. -
Page 25: Maintenance
• Change engine oil. Every 100 Hours • Replace fuel filter element. Every 100 Hours machine, obtain replacements from a Lincoln • Clean or replace air filter element. Every 100 Hours Distributor. (See Operating Manual Parts List.) • Spark Arrester... -
Page 26: Engine Oil Change
MAINTENANCE ENGINE OIL CHANGE 4. Screw on the new oil filter by hand, until the gasket contacts the filter mounting base, then use an oil filter Drain the oil while the engine is warm to assure rapid and socket tool to tighten the filter an additional 1/2 to 7/8 complete draining. -
Page 27: Air Filter Paper Element
MAINTENANCE AIR FILTER PAPER ELEMENT 5. Measure the plug gap with a feeler gauge. Correct as necessary by bending the side electrode. 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 2. -
Page 28: Fuel Filter
Adjustments to the engine are to be made only by a If battery cells are low, fill them to the neck of the filler Lincoln Service Center or an authorized Field Service hole with distilled water and recharge. If one cell is Shop. -
Page 29: Welder / Generator Maintenance
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. -
Page 30: 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. - Page 31 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...
- Page 32 5. 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...
- Page 33 6. Rotor winding open. 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...
- Page 34 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...
- 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 DIAGRAMS RANGER® 250...
- Page 44 F-10 F-10 DIAGRAMS RANGER® 250...
- Page 45 F-11 F-11 DIAGRAMS RANGER® 250...
- Page 46 F-12 F-12 DIMENSION PRINT RANGER® 250...
- Page 47 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
- Page 48 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
- Page 49 • 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...