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Lincoln Electric RANGER 225 User Manual

Lincoln Electric RANGER 225
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RANGER
®
225
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For Machines with Code Number 11597, 11734
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June, 2010
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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 thoughtful operation on
your part. $#$)#()!!
$%')$' '%' )(
&*%"#),)$*) '
# )( "#*! #)
(). %'*)$#( $#
)# )'$*$*). 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
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.

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Lincoln Electric RANGER 225 Specifications

General IconGeneral
Max Output225 Amps
Maximum Output225 Amps
Fuel TypeGasoline
TypeEngine Driven Welder
Welding ProcessesStick, TIG
EngineKohler CH440
Auxiliary Power120/240V AC
Weight215 kg
Dimensions (H x W x D)28 in (711 mm)

Summary

Safety Precautions

Proposition 65 Warnings

Warnings regarding potential carcinogens and reproductive harm from engine exhaust.

Engine Safety

Safety measures for operating engine-powered equipment, including ventilation and refueling.

Electric and Magnetic Fields (EMF)

Potential hazards of EMF fields, especially for pacemaker wearers, and methods to minimize exposure.

Electric Shock Hazards

Precautions and equipment to prevent electric shock while welding.

Arc Ray Protection

Essential protective measures against arc rays to prevent burns and eye damage.

Fumes and Gases Hazards

Risks associated with welding fumes and gases and necessary ventilation precautions.

Fire and Explosion Hazards

Risks of fire and explosion from welding sparks, hot materials, and flammable substances.

Compressed Gas Cylinder Safety

Precautions for handling compressed gas cylinders to prevent explosions and damage.

Electrical Equipment Safety

Safety guidelines for electrically powered equipment installation and grounding.

Customer Information

Customer Assistance Policy

Lincoln Electric's policy regarding customer advice and information on product use.

Product Registration and Information

Instructions for product registration, recording equipment details, and obtaining information.

Installation

Technical Specifications

Detailed specifications for the RANGER® 225, including engine, welder, generator, and physical dimensions.

Installation Safety Precautions

Critical safety warnings and guidelines for installing and operating the equipment.

Machine Grounding

Guidelines and requirements for properly grounding the welding machine.

Spark Arrester

Information on the requirement and installation of a spark arrester for gasoline engines.

Towing Recommendations

Guidance on recommended trailers and factors to consider for towing the equipment.

Vehicle Mounting

Safety precautions and guidelines for mounting the equipment on vehicles.

Pre-Operation Service

Essential checks and services before operating the machine, including fuel, oil, and battery.

Battery Connections

Instructions and cautions for properly connecting the battery terminals.

Welding Output Cables

Guidelines for connecting and selecting welding output cables based on length and current.

Engine Operation Angles and Lifting

Recommendations for operating the engine at angles, maintaining oil, and safe lifting procedures.

High Altitude and Exhaust Management

Considerations for high altitude operation and muffler pipe installation for exhaust directing.

Additional Installation Safety

Further safety advice for operation during installation.

Location, Ventilation, and Stacking

Guidelines for welder positioning, airflow, exhaust venting, and stacking limitations.

Wire Feeder Connections

Procedures for connecting Lincoln Electric wire feeders, including LN-15 and LN-25 models.

TIG Module Connection

Instructions for connecting the K930-2 TIG Module for TIG welding applications.

Additional Operation Safety

Further safety advice for operating the welder with panels and guards in place.

Welder Output Specifications

Details on maximum open circuit voltage, duty cycle, and output ratings for welding.

Auxiliary Power Operation

Information on using the RANGER® 225 as an AC power generator for auxiliary loads.

Receptacle Usage

Guidelines for using the 120/240V dual voltage and 120V duplex receptacles.

Motor Starting and Extension Cords

Information on starting motors and selecting appropriate extension cords for auxiliary power.

Electrical Device Compatibility

Table outlining common electrical devices and potential concerns when used with the RANGER® 225.

Simultaneous Welding and Auxiliary Power

Guidelines for operating welding and auxiliary power loads simultaneously, with current limitations.

Standby Power Connections

Information on using the RANGER® 225 for temporary, standby, or emergency power supply.

Connecting to Premises Wiring

Diagram and safety warning for connecting the RANGER® 225 to premises wiring by a licensed electrician.

Operation

Pre-Operation Safety

Essential safety precautions to read and follow before operating the machine.

General Description

Overview of the RANGER® 225 as a multiprocess arc welder and AC power generator.

Welder Controls Overview

Explanation of the function and operation of the welder's controls, including the engine switch.

Range Switch Function

How to use the Range switch to select amperage ranges for different welding processes.

Control Dial Adjustment

Using the Control dial for fine-tuning welding current and voltage settings.

Approximate Fuel Consumption

Table detailing the approximate fuel consumption of the RANGER® 225 under various operating conditions.

Starting and Stopping the Engine

Step-by-step instructions for starting and safely shutting down the engine, including choke usage.

Engine Break-In Period

Guidance on the engine break-in process, including recommended loads and oil checks.

Stick Welding Procedures

How to connect cables and set controls for stick welding with various electrode sizes.

Scratch Start TIG Welding

Instructions for initiating and performing scratch start TIG welds using the RANGER® 225.

TIG Tungsten Electrode Current Ranges

A table detailing typical current ranges for tungsten electrodes used in TIG welding.

Wire Feed Welding (Constant Voltage)

Procedures for wire feed welding, including recommended wire speeds and current ranges.

Welding Process Summary

A summary table comparing different welding processes, idle modes, and starting procedures.

Arc Gouging

Guidelines for performing limited arc gouging using the RANGER® 225.

Accessories

Optional Equipment

A list of optional field-installable equipment to enhance the RANGER® 225 capabilities.

Recommended Equipment

Recommended accessories for Stick, Wire Feed, and TIG welding processes.

Maintenance

Maintenance Safety Precautions

Essential safety guidelines to follow before performing any maintenance on the equipment.

Routine Maintenance Tasks

Daily checks and tasks, including fuel refilling and oil level checks.

Engine Oil Change Procedure

Step-by-step instructions for draining and refilling the engine oil.

Engine Oil Refill Capacities

Specifications for the amount of oil required for engine oil changes, with and without filter replacement.

Air Cleaner and Other Maintenance

Procedures for maintaining the air cleaner and other components, referring to the engine manual.

Selector and Polarity Switch Maintenance

Guidance on maintaining the contacts of the selector and polarity switches for optimal performance.

Engine Adjustments and Overspeed Warning

Information on engine adjustments, maximum speed limits, and the hazards of overspeeding.

Slip Rings Maintenance

Inspection and maintenance of slip rings and brushes, with a caution against polishing while running.

Battery Safety and Connection

Precautions for battery installation, charging, and connection to prevent explosions and damage.

Engine Maintenance Parts

A list of common replacement parts for the Kohler CH23S engine.

Troubleshooting

Using the Troubleshooting Guide

Instructions on how to effectively use the troubleshooting guide to diagnose and resolve machine malfunctions.

No Output Power or Auxiliary Power

Possible causes and recommended actions for lack of welder output or auxiliary power.

Engine Idle Issues

Troubleshooting steps for when the engine fails to idle down or go to high idle.

Auxiliary Power and High Idle Issues

Troubleshooting for engine high idle issues when using auxiliary power.

Engine Cranking and Starting Problems

Diagnosing issues related to the engine not cranking, cranking slowly, or being hard to start.

Engine Shutdown and Power Issues

Identifying causes for the engine shutting down or not developing full power.

Diagrams

Wiring Diagram

Detailed wiring schematic for the RANGER® 225, illustrating electrical connections and components.

Wire Feeder Connection Diagram

Diagram showing the connection of LN-25 or LN-15 wire feeders to the engine welder.

Dimension Print

Physical Dimensions and Mounting

A print showing the physical dimensions, center of gravity, and mounting hole locations for the RANGER® 225.

Multilingual Safety Warnings

General Safety Precautions

Essential safety warnings presented in multiple languages regarding electrical shock, flammability, and personal protection.

Operational Safety Instructions

Safety instructions in multiple languages covering fume avoidance, servicing power, and panel operation.

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