Instruction/ maintenance manual of the product IM931 Lincoln Electric
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Ranger 250 LPG OPERA TOR’S MANUAL IM931 September, 2006 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part.
FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment.
vi vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .....................................................
vii vii T ABLE OF CONTENTS Maintenance ......................................................................................................Section D Safety Precautions .................................................................................
Make/Model Description Horsepower Operating Displacement cu. in.(cu. cm) Starting Capacities @ 3600 RPM SPEED Bore x Stroke in.(mm) System RANGER 250 LPG 1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity.
A-2 INST ALLA TION RANGER 250 LPG A-2 MACHINE SPECIFICA TIONS - RANGER 250 LPG Engine (K2336-2) RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS (2) 120VAC GFCI Two 20AMP for Two Dup.
A-3 INST ALLA TION RANGER 250 LPG A-3 • Lift only with equipment of ade- quate lifting capacity. • Be sure machine is stable when lifting. • Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder.
A-4 INST ALLA TION RANGER 250 LPG A-4 Be certain that the cylinder valve is CLOSED before attempting to attach the fuel supply hose coupler to the cylinder.
A-5 INST ALLA TION RANGER 250 LPG A-5 OIL The RANGER 250 LPG is shipped with the engine crankcase filled with high quality SAE 10W-30 oil. Check the oil level before starting the engine. If it is not up to the full mark on the dip stick, add oil as required.
A-6 INST ALLA TION RANGER 250 LPG A-6 ELECTRICAL CONNECTIONS MACHINE GROUNDING Because this portable engine driven welder creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.
A-7 INST ALLA TION RANGER 250 LPG A-7 AUXILIAR Y POWER RECEPT ACLES Start the engine and set the “IDLER” control switch to the “High Idle” mode. Voltage is now correct at the receptacles for auxiliary power. This must be done before a tripped GFCI receptacle can be reset proper- ly.
A-8 INST ALLA TION RANGER 250 LPG A-8 240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS.
A-9 INST ALLA TION RANGER 250 A-9 CONNECTION OF LINCOLN ELEC- TRIC WIRE FEEDERS Connection of LN-7 or LN-8 to the RANGER 250 LPG 1. Shut the welder off. 2. Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in Section F 3.
A-10 INST ALLA TION RANGER 250 LPG A-10 Connection of Prince Spool Gun to the RANGER 250 LPG Connection of the Prince XL Spool Gun requires the use of the K1849-1 Adapter Module.
B-1 OPERA TION RANGER 250 LPG B-1 GENERAL DESCRIPTION The RANGER 250 LPG is an engine powered DC multi-process welding power source and 120 / 240 volt AC power generator. The engine drives a genera- tor that supplies three phase power for the DC weld- ing circuit and single phase power for the AC auxiliary outlets.
B-2 OPERA TION B-2 WELDING CONTROLS: 1. OUTPUT CONTROL: The CONTROL dial pro- vides continuous control of the welding current or weld- ing voltage depending on the selected welding mode.
B-3 OPERA TION B-3 4. WELD OUTPUT TERMINALS WITH FLANGE NUT : Provides a connection point for the electrode and work cables. Output Stud covers porvided on code 11272 and above. 5. GROUND STUD: Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure.
B-4 OPERA TION B-4 Operating the starter motor for more than 5 sec- onds can damage the motor. If the engine fails to start, release the switch and wait 10 seconds before operation the starter again. Do NOT push the START button while the engine is running because this can damage the ring gear and/or the starter motor.
(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.
B-6 OPERA TION B-6 ARC GOUGING The RANGER 250 LPG can be used for limited arc gouging. For optimal performance, set the MODE switch to CC-STICK and the ARC CONTROL to +10.
C-1 ACCESSORIES C-1 RECOMMENDED OPTIONAL EQUIPMENT K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.
D-1 MAINTENANCE D-1 RANGER 250 LPG KOHLER ENGINE (1) Service more frequently when used in dusty areas and/or at high ambient temperatures. SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine.
D-2 MAINTENANCE D-2 ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining. • Remove the oil filler cap and dipstick. Remove the yellow cap from the oil drain valve and attach the flexible drain tube supplied with the machine.
D-3 MAINTENANCE D-3 AIR FIL TER P APER ELEMENT 1. Loosen the cover retaining knob and remove the cover. 2. Remove the pre-cleaner from the paper element. 3. Remove the element cover nut, element cover, and paper element. 4. Do not wash the paper element or use pressurized air, as this will damage the element.
D-4 MAINTENANCE D-4 ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop. BA TTER Y MAINTENANCE To access the battery, Remove the 2 screws from the rear battery tray using a screwdriver or a 3/8" socket.
D-5 MAINTENANCE D-5 GFCI RECEPT ACLE TESTING AND RESET- TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage.
E-1 TROUBLESHOOTING E-1 RANGER 250 LPG If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-2 TROUBLESHOOTING E-2 RANGER 250 LPG Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-3 TROUBLESHOOTING E-3 RANGER 250 LPG Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-4 TROUBLESHOOTING E-4 RANGER 250 LPG Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
E-5 TROUBLESHOOTING E-5 RANGER 250 LPG Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
F-1 DIAGRAMS F-1 RANGER 250 LPG.
F-2 DIAGRAMS F-2 RANGER 250 LPG.
F-3 DIAGRAMS F-3 RANGER 250 LPG.
F-4 DIAGRAMS F-4 RANGER 250 LPG.
F-5 DIAGRAMS F-5 RANGER 250 LPG.
F-6 DIAGRAMS F-6 RANGER 250 LPG or ser vice t his equi pm ent. On ly qualified personnel should install,use Keep away from movi ng pa rts. Keep guards in place. MOVING PART S can injure WA R N I N G Do not touch electrically live pa rts. before servicing.
F-7 DIAGRAMS F-7 RANGER 250 LPG.
F-8 DIAGRAMS F-8 RANGER 250 LPG.
F-9 DIAGRAMS F-9 RANGER 250 LPG.
F-10 DIAGRAMS F-10 RANGER 250 LPG.
F-11 DIAGRAMS F-11 RANGER 250 LPG NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement.
M19 41 0 E CIRCU IT BREAKERS 41.2 0 17.5 0 19.5 0 TRUC K/U ND E RC A RR IAG E MOU NTING HOLE S 7.22 24.8 6 2.62 5.57 30.6 5 NOTE: CASE F RONT GRAPHI CS MAY NOT MAT CH ALL CODES.
NOTES RANGER 250 LPG.
NOTES RANGER 250 LPG.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• 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.
An important point after buying a device Lincoln Electric IM931 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric IM931 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric IM931 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric IM931 you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric IM931 will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric IM931, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric IM931.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric IM931. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric IM931 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
