SVM150-ASeptember, 2002Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, your overall
ADDITIONAL SAFETY PRECAUTIONSFALLING EQUIPMENT can causeinjury.• Do not lift this machine using lift bail ifit is equipped with a heavy accessorysuch
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TROUBLESHOOTING & REPAIRF-51 F-51RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-52 F-52RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-53 F-53RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-54 F-54RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
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TROUBLESHOOTING & REPAIRF-56 F-56RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
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TROUBLESHOOTING & REPAIRF-58 F-58RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-59 F-59RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
BATTERY CONNECTIONSBATTERY ACID CAN BURN EYES ANDSKIN.• Wear gloves and eye protection and becareful when working near a battery.Follow the instructi
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TROUBLESHOOTING & REPAIRF-61 F-61RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-62 F-62RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-63 F-63RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-64 F-64RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-65 F-65RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-66 F-66RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-67 F-67RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
RETEST AFTER REPAIRRetest a machine:• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect
G-1 G-1RANGER 250Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCELECTRICAL DIAGRAMSTABLE OF CONTENTS -ELECTRICAL D
To prevent dangerous electric shock, other equipmentto which this engine driven welder supplies powermust:a) Be grounded to the frame of the welder us
ELECTRICAL DIAGRAMSG-2RANGER 250WIRING DIAGRAM - RANGER 250 KOHLERCONTACTORCONTROLSHOWN IN"WELDING ON"POSITIONWIRE FEED POWER WINDING4
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ELECTRICAL DIAGRAMSG-9RANGER 250SCHEMATIC - CHOPPER PRINTED CIRCUIT BOARDFILENAME: M19462_1BA10.0R510.0R9(UNLESS OTHERWISE SPECIFIED)UNLESS OTHE
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ELECTRICAL DIAGRAMSG-11RANGER 250SCHEMATIC - WELD CONTROL PRINTED CIRCUIT BOARD - SHEET 1G-11NOTE: This diagram is for reference only. It may not be a
TABLE A.1 – TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLESCableCable Size for Length250 Amps100% Duty Cycle0-100 ft. (0-30 meters) 1 AWG100-200 ft
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SVM ERROR REPORTING FORMWe need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that wo
INSTALLATIONA-8 A-8RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mas
Section B-1 Section B-1RANGER 250TABLE OF CONTENTS- OPERATION SECTION -Operation...
OPERATING INSTRUCTIONSRead and understand this entire section before operat-ing your Ranger 250. SAFETY INSTRUCTIONSDo not attempt to use this equipme
DESIGN FEATURES• Single, full-range output control dial.• 4 welding modes: CC-stick, downhill stick welding onpipe, CV wire welding and Touch-Start
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OPERATIONB-5 B-5RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master
SAFETYi iRANGER 250FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work require
1. Remove the fuel tank cap.2. Fill the tank approximately 4 inches (100mm) fromthe top of the filler neck to allow for fuel expansion.(Observe the fu
WELDER OPERATIONGENERAL INFORMATION• Do not touch electrically live parts or elec-trodes with your skin or wet clothing.• Do not breathe welding fum
STICK WELDINGThe Ranger 250 can be used with a broad range of DCstick electrodes. The MODE switch provides two stick welding settingsas follows:CONST
TIG WELDINGThe TOUCH START TIG setting of the MODE switch isfor DC TIG (Tungsten Inert Gas) welding. To initiate aweld, the OUTPUT control is first s
The 240 VAC output can be split to provide two sepa-rate 120 VAC outputs with a maximum permissible cur-rent of 33 amps per output to two separate 20
TABLE OF CONTENTS- ACCESSORIES -Accessories ...
OPTIONS/ACCESSORIESFIELD INSTALLED OPTIONSThe following options/accessories are available foryour Ranger 250 from your local Lincoln distributor.K957-
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERSELECTRIC SHOCK can kill.• Do not operate with panels open.• Disconnect NEGATIVE (-) BATTERYLEAD before serv
CONNECTION OF THE LN-25 TO THERANGER 250 “ACROSS THE ARC” (SEE FIGURE C.2.)1. Shut the welder off.2. Connect the electrode cable from the LN-25 to the
ACCESSORIESC-5 C-5RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast
SAFETYii iiRANGER 250ARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the ar
CONNECTION OF THE LN-25 TO THE RANGER 250 “ACROSS THE ARC” WITH K857 REMOTE CONTROL(SEE FIGURE C.4.)1. Shut the welder off.2. Connect the electrode ca
CONNECTION OF THE LN-7 TO THERANGER 250 USING K584 CONTROLCABLE (SEE FIGURE C.5.)NOTE: If your LN-7 comes equipped with a K291 orK404 input cable, ref
CONNECTION OF THE LN-8 TO THE RANGER 250 USING K595 CONTROLCABLE (SEE FIGURE C.6.)NOTE: If your LN-8 comes equipped with a K291 orK404 input cable, re
ACCESSORIESC-9 C-9RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast
C-10NOTES RANGER 250C-10Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection D-1 Section D-1RANGER 250TABLE OF CONTENTS-MAINTENANCE-Main
SAFETY PRECAUTIONS• Have qualified personnel do all maintenance andtroubleshooting work.• Turn the engine off before working inside themachine.• Re
MAINTENANCED-3 D-3RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Mast
ENGINE OIL CHANGEDrain the oil while the engine is warm to assure rapidand complete draining.1. Remove the oil filler cap and dipstick. Remove theyell
Air Filter Paper Element Service1. Loosen the cover retaining knob and remove thecover.2. Remove the pre-cleaner from the paper element.3. Remove the
RANGER 250FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. I
BATTERY MAINTENANCETo access the battery, remove the screws from the rearbattery tray using a screwdriver or a 3/8" socket. Slidethe battery tra
WELDER/GENERATOR MAINTENANCESTORAGEStore the Ranger 250 in clean, dry, protected areas.CLEANINGBlow out the generator and controls periodically withlo
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Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection E-1 Section E-1RANGER 250Theory of Operation ...
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THEORY OF OPERATIONE-4 E-4RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return
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RANGER 250PULSE WIDTH MODULATIONThe term PULSE WIDTH MODULATION is used todescribe how much time is devoted to conduction in thecycle. Changing the p
CHOPPER TECHNOLOGYFUNDAMENTALSThe new era of welding machines such as the Ranger250 employ a technology whereby a DC source isturned on and off (chopp
SAFETYiv ivRANGER 250PRÉCAUTIONS DE SÛRETÉPourvotre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques
E-8NOTES RANGER 250E-8Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master T
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSection F-1 Section F-1RANGER 250Troubleshooting & Repair Secti
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F-8 F-8RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Retu
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MASTER TABLE OF CONTENTS FOR ALL SECTIONSv vRANGER 250PageSafety...
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TROUBLESHOOTING & REPAIRF-12 F-12RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
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TROUBLESHOOTING & REPAIRF-15 F-15RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-16 F-16RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
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TABLE OF CONTENTS- INSTALLATION SECTION -Section A-1 Section A-1RANGER 250Installation...
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TROUBLESHOOTING & REPAIRF-32 F-32RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-33 F-33RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-34 F-34RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TABLE F.1. – ANALOG PC BOARD OUTPUT VOLTAGE TABLETEST POINTS COMPONENT TESTED VOLTAGE READING1J42 to 6J42 Chopper Power Supply +20 VDC2J42 to 7J42 Wel
TROUBLESHOOTING & REPAIRF-36 F-36RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-37 F-37RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-38 F-38RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
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Read this entire installation section before youstart installation.SAFETY PRECAUTIONSDo not attempt to use this equipment until you havethoroughly rea
TROUBLESHOOTING & REPAIRF-40 F-40RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-41 F-41RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
TROUBLESHOOTING & REPAIRF-42 F-42RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
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TROUBLESHOOTING & REPAIRF-44 F-44RANGER 250Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master
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