Lincoln Electric Welder SVM150 A User Manual
RETURN TO MAIN INDEX  
SVM150-A  
September, 2002  
TM  
Ranger 250  
For use with machines having Code Numbers: 10654  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However,  
your overall safety can be in-  
creased by proper installation . . .  
and thoughtful 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.  
SERVICE MANUAL  
Copyright © 2002 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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ii  
ii  
SAFETY  
ARC RAYS can burn.  
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.  
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.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5.b. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating  
products.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iii  
iii  
SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact can  
cause overheating and create a fire hazard.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate circuits.  
This can create fire hazards or overheat lifting chains or  
cables until they fail.  
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.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iv  
iv  
SAFETY  
zones où l’on pique le laitier.  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
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:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
8. S’assurer que la masse est connectée le plus prés possible de  
la zone de travail qu’il est pratique de le faire. Si on place la  
masse sur la charpente de la construction ou d’autres endroits  
éloignés de la zone de travail, on augmente le risque de voir  
passer le courant de soudage par les chaines de levage,  
câbles de grue, ou autres circuits. Cela peut provoquer des  
risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher met-  
allique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble de  
soudage et la machine à souder en bon et sûr état defonc-  
tionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à soud-  
er parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
11. Pour obtenir de plus amples renseignements sur la sûreté, voir  
le code “Code for safety in welding and cutting” CSA Standard  
W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
Mar. ‘93  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
v
v
MASTER TABLE OF CONTENTS FOR ALL SECTIONS  
RETURN TO MAIN INDEX  
Page  
Safety.................................................................................................................................................i-iv  
Installation.............................................................................................................................Section A  
Technical Specifications..............................................................................................................A-2  
Safety Precautions......................................................................................................................A-3  
Location and Ventilation..............................................................................................................A-3  
Pre-Operation Engine Service ....................................................................................................A-4  
Electrical Output Connections.....................................................................................................A-5  
Operation...............................................................................................................................Section B  
Safety Instructions.......................................................................................................................B-2  
General Description ....................................................................................................................B-2  
Design Features..........................................................................................................................B-3  
Controls and Settings..................................................................................................................B-3  
Engine Operation ........................................................................................................................B-5  
Welder Operation........................................................................................................................B-7  
Auxiliary Power ...........................................................................................................................B-9  
Accessories ..........................................................................................................................Section C  
Maintenance..........................................................................................................................Section D  
Theory of Operation .............................................................................................................Section E  
Troubleshooting and Repair ................................................................................................Section F  
Electrical Diagrams..............................................................................................................Section G  
Parts Manual ................................................................................................................................P-358  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Section A-1  
Section A-1  
TABLE OF CONTENTS  
- INSTALLATION SECTION -  
Installation.............................................................................................................................Section A  
Technical Specifications..............................................................................................................A-2  
Safety Precautions......................................................................................................................A-3  
Location and Ventilation..............................................................................................................A-3  
Storing ..................................................................................................................................A-3  
Stacking................................................................................................................................A-3  
Angle of Operation................................................................................................................A-3  
Lifting ....................................................................................................................................A-3  
Additional Safety Precautions .....................................................................................................A-4  
High Altitude Operation.........................................................................................................A-4  
High Temperature Operation ................................................................................................A-4  
Towing...................................................................................................................................A-4  
Pre-Operation Engine Service ....................................................................................................A-4  
Oil .........................................................................................................................................A-4  
Fuel.......................................................................................................................................A-4  
Engine Cooling System ........................................................................................................A-4  
Battery Connections .............................................................................................................A-5  
Muffler Outlet Pipe................................................................................................................A-5  
Spark Arrester.......................................................................................................................A-5  
High Frequency Generators for TIG Applications.................................................................A-5  
Remote Control.....................................................................................................................A-5  
Welding Terminals ................................................................................................................A-5  
Electrical Output Connections.....................................................................................................A-5  
Machine Grounding ..............................................................................................................A-5  
Welding Output Cables.........................................................................................................A-6  
Cable Installation ............................................................................................................A-7  
Auxiliary Power Receptacles................................................................................................A-7  
Standby Power Connections ................................................................................................A-7  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-2  
A-2  
INSTALLATION  
TECHNICAL SPECIFICATIONS - RANGER 250 (K1725-1/K1725-2)  
INPUT - GASOLINE ENGINE  
Make/Model Description Speed (RPM) Displacement  
cu. in. (cu. cm.)  
Starting  
System  
Capacities  
2 cylinder  
High Idle 3700  
Full Load 3500  
Low Idle 2400  
44 (714) - Onan 12 VDC Battery &  
38 (624) - Kohler Starter  
Fuel: 12 gal.  
45.4 L  
Onan P216  
(K1725-1)  
16 HP @  
3600 RPM  
(Onan)  
Bore x Stroke inch (Group 58; 435 cold Oil: 1.8 Qts.  
(mm)  
crank amps)  
1.7 L (Onan)  
3.25 x 2.625  
(83 x 67) (Onan)  
Battery Charger  
20 A. regulated (K1725-1)  
15 A. regulated (K1725-2)  
Oil: 2.0 Qts.  
1.9 L (Kohler)  
20 HP @  
3600 RPM  
(Kohler)  
Kohler CH20  
(K1725-2)  
3.03 x 2.64  
Cooling System:  
(77 x 67) (Kohler) (Push Button Start) Air-Cooled  
RATED OUTPUT - WELDER  
Welding Output  
Volts at Rated Amps  
Duty Cycle Max.  
OCV @ 3700 RPM  
CC STICK & PIPE DC Output  
STICK / PIPE Output Range  
TIG Output Range  
CV WIRE DC Output  
CV WIRE Output Range  
25 Volts at 250 Amps  
20 to 250 Amps  
20 to 250 Amps  
25 Volts at 250 Amps  
14 to 28 Volts  
100%  
100%  
80 Volts  
OUTPUT - GENERATOR  
Auxiliary Power1  
8,000 Watts, 60 Hz  
120/240 Volts  
100% Duty Cycle  
PHYSICAL DIMENSIONS  
Height  
Width  
Depth  
Weight  
30.00* in.  
762.0 mm  
21.50 in.  
546.0 mm  
42.25 in.  
1073.0 mm  
452 lbs. (205 kg.) K1725-1  
434 lbs. (197 kg.) K1725-2  
* Top of enclosure, add 6.0” (152 mm) for exhaust  
ENGINE COMPONENTS  
Lubrication  
Valve Lifters  
Fuel System  
Governor  
Full Pressure  
with Full Flow Filter  
Solid (Onan)  
Hydraulic (Kohler)  
Vacuum Pulse Pump (Onan)  
Mechanical Fuel Pump (Kohler)  
Mechanical Governor  
5% Regulation  
Air Cleaner  
Engine Idler  
Muffler  
Engine Protection  
Duel Element  
Automatic Idler  
Low noise muffler: Top outlet  
can be rotated. Made from  
long life, aluminized steel.  
Shutdown on low oil  
pressure.  
Receptacles  
Auxiliary Power Circuit Breaker  
Other Circuit Breakers  
Two 120 VAC Duplex  
(5-20R)  
Two 20 Amp for Two Duplex  
Receptacle  
25 Amp for Battery Charging  
Circuit  
One 120/240 VAC Dual  
Voltage  
Two 35 Amp for Dual Voltage  
150 Amp for 42 Volt Wire Feeder  
Power  
Full KVA (14-50R)  
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. When welding,  
available auxiliary power will be reduced.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-3  
A-3  
INSTALLATION  
Read this entire installation section before you  
start installation.  
STORING  
1. Store the machine in a cool, dry place when it is  
not in use. Protect it from dust and dirt. Keep it  
where it can’t be accidentally damaged from con-  
struction activities, moving vehicles, and other haz-  
ards.  
SAFETY PRECAUTIONS  
WARNING  
2. If you will be storing the machine for over 30 days,  
you should drain the fuel to protect fuel system and  
carburetor parts from gum deposits. Empty all fuel  
from the tank and run the engine until it stops from  
lack of fuel. If you prefer, you can treat the gaso-  
line with a stabilizer to prevent deterioration rather  
than drain the system. Follow the stabilizer manu-  
facturer’s instructions. Add the correct amount of  
stabilizer for the size of the fuel tank. Fill the tank  
with clean, fresh gasoline. Run the engine for two  
to three minutes to circulate the stabilizer through  
the carburetor.  
Do not attempt to use this equipment until you have  
thoroughly read the engine manufacturer’s manual  
supplied with your welder. It includes important safety  
precautions, detailed engine starting, operating and  
maintenance instructions and parts lists.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live  
parts or electrode with skin or  
wet clothing.  
• Insulate yourself from work and  
ground.  
3. While the engine is still warm, drain the oil and refill  
with fresh 10W30 oil. Change the oil filter.  
• Always wear dry insulating  
gloves.  
4. Remove the spark plugs and add one to two table-  
spoons of engine oil or rust inhibitor into each cylin-  
der. Replace the spark plugs but do not connect  
the plug leads. Crank the engine two or three  
times to distribute the oil.  
ENGINE EXHAUST can kill.  
• Use in open, well ventilated  
areas or vent exhaust outside.  
• Do not stack anything near the  
engine.  
5. Clean any dirt or debris from the cylinder and cylin-  
der head fins and other exterior surfaces.  
MOVING PARTS can injure.  
• Do not operate with doors open  
or guards off.  
• Stop engine before servicing.  
• Keep away from moving parts.  
STACKING  
Ranger 250 machines CANNOT be stacked.  
ANGLE OF OPERATION  
See additional safety information at the front of this  
manual.  
Engines are designed to run in the level condition,  
which is where the optimum performance is achieved.  
The maximum angle of continuous operation is 15  
degrees in any direction. If the engine is to be operat-  
ed at an angle, provisions must be made for checking  
and maintaining the oil level at the normal (FULL) oil  
capacity in the crankcase.  
Only qualified personnel should install, use, or  
service this equipment.  
LOCATION AND VENTILATION  
When operating the welder at an angle, the effective  
fuel capacity will be slightly less than the specified 12  
gallons (45.4 liters).  
The welder should be located to provide an unrestrict-  
ed flow of clean, cool air to the cooling air inlets and to  
avoid restricting the cooling air outlets. Also, locate the  
welder so that the engine exhaust fumes are properly  
vented to an outside area.  
LIFTING  
The Ranger 250 weighs approximately 452 lbs./205 kg.  
with a full tank of gasoline. A lift bail is mounted to the  
machine and should always be used when lifting it.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-4  
A-4  
INSTALLATION  
ADDITIONAL SAFETY PRECAUTIONS PRE-OPERATION ENGINE SERVICE  
Read and understand the information about the gaso-  
line engine in the Operation and Maintenance sec-  
WARNING  
tions of this manual before you operate the Ranger  
250.  
FALLING EQUIPMENT can cause  
injury.  
• Do not lift this machine using lift bail if  
it is equipped with a heavy accessory  
such as trailer or gas cylinder.  
WARNING  
• Keep hands away from the engine muffler or HOT  
engine parts.  
• Lift only with equipment of adequate lifting capacity.  
• Be sure machine is stable when lifting.  
• Stop the engine and allow it to cool before fueling.  
• Do not smoke when fueling.  
HIGH ALTITUDE OPERATION  
• Fill the fuel tank at a moderate rate and do not over-  
fill.  
At higher altitudes, output de-rating may be necessary.  
For maximum rating, de-rate the welder output 3.5%  
for every 1000 ft. (305m). Contact an authorized  
engine service shop for modifications to operate above  
5,000 ft. (1525m).  
• Wipe up spilled fuel and allow the fumes to clear  
before starting the engine.  
• Keep sparks and flame away from the fuel tank.  
• Remove the fuel cap slowly to release pressure.  
HIGH TEMPERATURE OPERATION  
OIL  
At temperatures above 30°C, output de-rating is nec-  
essary. For maximum output ratings, de-rate the  
welder output 5% for every 10°C above 30°C.  
The Ranger 250 is shipped with the engine  
crankcase filled with high quality SAE 10W-  
30 oil (API class CD or better). CHECK THE OIL  
LEVEL BEFORE YOU START THE ENGINE. If it is  
not up to the FULL mark on the dipstick, add oil as  
required. Check the oil every four hours of running  
time during the first 25 running hours. Refer to the  
engine operator’s manual for specific oil recommenda-  
tions and break-in information. The oil change interval  
is dependent on the quality of the oil and the operating  
environment. Refer to the engine operator’s manual  
for the proper service and maintenance intervals.  
TOWING  
The recommended trailer for use with this equipment  
for road, in-plant and yard towing by a vehicle1 is  
Lincoln’s K957-1. If the user adapts a non-Lincoln trail-  
er, he must assume responsibility that the method of  
attachment and usage does not result in a safety haz-  
ard nor damage the welding equipment. Some of the  
factors to be considered are as follows:  
1. Design capacity of trailer vs. weight of Lincoln  
equipment and likely additional attachments.  
FUEL  
2. Proper support of, and attachment to, the base of  
the welding equipment so there will be no undue  
stress to the framework.  
Use gasoline fuel only.  
Fill the fuel tank with clean, fresh fuel. The  
capacity of the fuel tank is 12 gallons (45.4  
liters).  
3. Proper placement of the equipment on the trailer to  
insure stability side to side and front to back when  
being moved and when standing by itself while  
being operated or serviced.  
NOTE: The fuel tank is mounted below the engine, so  
a fuel shutoff valve is not required.  
4. Typical conditions of use such as travel speed,  
roughness of surface on which the trailer will be  
operated, environmental conditions, and likely  
maintenance.  
ENGINE COOLING SYSTEM  
Air to cool the engine is drawn in through the lower set  
of louvers on the case back. It is important that the  
intake air is not restricted. Allow a minimum clearance  
of 2 feet (0.6m) from the case back to a vertical sur-  
face.  
5. Conformance with federal, state and local laws.1  
1 Consult applicable federal, state and local laws regarding specific  
requirements for use on public highways.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-5  
A-5  
INSTALLATION  
BATTERY CONNECTIONS  
HIGH FREQUENCY GENERATORS FOR  
TIG APPLICATIONS  
WARNING  
The K930-2 TIG Module is suitable for use with the  
Ranger 250. The Ranger 250 and any high frequency  
generating equipment must be properly grounded.  
See the K930-2 operating manual for complete instruc-  
tions on installation, operation, and maintenance.  
BATTERY ACID CAN BURN EYES AND  
SKIN.  
• Wear gloves and eye protection and be  
careful when working near a battery.  
Follow the instructions printed on the  
battery.  
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 K963-  
2 hand Amptrol.  
Use caution as the electrolyte is a strong acid that can  
burn skin and damage eyes.  
The Ranger 250 is shipped with the negative battery  
cable disconnected. Make certain that the RUN-STOP  
switch is in the STOP position. Remove the screws  
from the rear battery tray using a screwdriver or a 3/8"  
socket. Attach the negative battery cable to the nega-  
tive battery terminal and tighten using a socket or  
wrench.  
When in the CC-STICK, PIPE, and CV-WIRE modes  
and when a remote control is connected to the  
Amphenol, the auto-sensing circuit in the Ranger 250  
automatically switches the OUTPUT control from con-  
trol at the welder to remote control.  
The 14-pin connector is used to directly connect a wire  
feeder. In the CV-WIRE mode, the Ranger 250 auto-  
sensing circuit automatically makes the Ranger 250  
OUTPUT control inactive and the wire feeder voltage  
control active when the control cable is connected to  
the 14-pin connector.  
NOTE: This machine is furnished with a wet charged  
battery; if unused for several months, the battery may  
require a booster charge. Be careful to charge the bat-  
tery with the correct polarity. See the battery charging  
instructions in the Maintenance section.  
NOTE: When a wire feeder with a built in welding volt-  
age control is connected to the 14-pin connector, do  
NOT connect anything to the 6-pin connector.  
MUFFLER OUTLET PIPE  
Using the clamp provided, secure the outlet pipe to the  
outlet tube with the pipe positioned to direct the ex-  
haust in the desired direction. Tighten using a socket or  
wrench.  
WELDING TERMINALS  
The Ranger 250 is equipped with a toggle switch for  
selecting “hot” welding terminals when in the “WELD  
TERMINALS ON” position or “cold” welding terminals  
when in the “REMOTELY CONTROLLED” position.  
SPARK ARRESTER  
Some federal, state or local laws may require spark  
arresters in locations where unarrested sparks may  
present a fire hazard. The standard muffler included  
with this welder does not qualify as a spark arrester.  
When required by local regulations, a suitable spark  
arrester, such as the S24647, must be installed and  
properly maintained. See the Accessories section for  
more information.  
ELECTRICAL OUTPUT  
CONNECTIONS  
See Figure A.1 for the location of the 120 and 240 volt  
receptacles, weld output terminals, and ground stud.  
CAUTION  
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 con-  
nected to premises wiring (home, shop, etc.)  
An incorrect spark arrester may lead to engine damage  
or may adversely affect performance.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-6  
A-6  
INSTALLATION  
To prevent dangerous electric shock, other equipment  
to which this engine driven welder supplies power  
must:  
In general, if the machine is to be grounded, it should  
be connected with a #8 or larger copper wire to a solid  
earth ground such as a metal water pipe going into the  
ground for at least ten feet and having no insulated  
joints, or to the metal framework of a building which  
has been effectively grounded. The U.S. National  
Electrical Code lists a number of alternate means of  
grounding electrical equipment. A machine grounding  
a) Be grounded to the frame of the welder using a  
grounded type plug.  
b) Be double insulated.  
stud marked with the  
ground symbol is provided  
on the front of the welder.  
WARNING  
WELDING OUTPUT CABLES  
Do not ground the machine to a pipe that carries explo-  
sive or combustible material.  
With the engine off, connect the electrode and work  
cables to the output terminals. The welding process  
dictates the polarity of the electrode cable. These con-  
nections should be checked periodically and tightened  
with a wrench.  
When this welder is mounted on a truck or trailer, its  
frame must be securely connected to the metal frame  
of the vehicle. When connected to premises wiring  
such as that in a home or shop, the welder frame must  
be connected to the system earth ground. See further  
connection instructions in the section entitled Standby  
Power Connections as well as the article on ground-  
ing in the latest U.S. National Electrical Code and the  
local code.  
Table A.1 lists recommended cable sizes and lengths  
for rated current and duty cycle. Length refers to the  
distance from the welder to the work and back to the  
welder. Cable diameters are increased for long cable  
lengths to reduce voltage drops. Avoid coiling long  
cables on the machine when welding.  
FIGURE A.1 – RANGER 250 OUTPUT CONNECTIONS  
G3668 VM  
K
NO.- CODE - SERIAL NO.  
CHOKE  
START  
HIGH  
RUN  
Hobbs  
QUARTZ  
IDLER  
0
0
0
0
0
0
HOURS  
AUTO  
STOP  
1. 120 VAC  
RECEPTACLES  
OUTPUT  
22 CV  
155 CC  
20 CV  
120 CC  
24 CV  
190 CC  
17 CV  
85 CC  
2. 120/240 VAC  
RECEPTACLES  
26 CV  
220 CC  
14 CV  
50 CC  
12 CV  
20 CC  
NRTL/C  
3. WELD OUTPUT  
TERMINALS  
28 CV  
250 CC  
NEUTRAL GROUND TO FRAME  
THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA  
WELD MODE  
ARC CONTROL  
-4  
0
+2  
+4  
-2  
WELD WIRE FEEDER  
TERMINALS ON VOLTMETER  
CV-WIRE  
PIPE  
4. GROUND STUD  
+6  
+8  
-6  
-8  
CC-STICK  
TOUCH START TIG  
REMOTELY  
CONTROLLED  
+10  
SOFT -10  
CRISP  
CIRCUIT  
BREAKERS  
120/240 V  
120 V  
1
2
SIMULTANEOUS WELDING AND POWER  
WELD CURRENT  
AMPS  
AUX. POWER  
WATTS  
240 V. RECEPTACLE  
AMPS  
0
33  
21  
13  
6
8000  
5000  
3000  
1500  
0
100  
150  
200  
250  
0
AUXILIARY POWER RATING  
WELDER OUTPUT RATING  
WATTS  
8,000  
DUTY CYCLE  
VOLTS  
AMPS  
DUTY CYCLE  
VOLTS  
100%  
120/240  
250 DC  
100%  
25  
AVAILABLE POWER IS REDUCED WHILE WELDING  
SINGLE PHASE 60 HZ  
80V MAX OCV AT RATED 3700 RPM  
4
3
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-7  
A-7  
INSTALLATION  
TABLE A.1 – TOTAL COMBINED LENGTH  
OF ELECTRODE AND WORK CABLES  
two separate 120 VAC branch circuits (these circuits  
cannot be paralleled). Output voltage is within ±10% at  
all loads up to rated capacity.  
Cable Size for  
250 Amps  
100% Duty Cycle  
Cable  
Length  
The 120 VAC auxiliary power receptacles should only  
be used with three-wire grounded type plugs or  
approved double insulated tools with two-wire plugs.  
The current rating of any plug used with the system  
must be at least equal to the current capacity of the  
associated receptacle.  
0-100 ft. (0-30 meters)  
1 AWG  
1 AWG  
100-200 ft. (30-46 meters)  
150-200 ft. (46-61 meters)  
1/0 AWG  
NOTE: The 240 VAC receptacle has two 120 VAC cir-  
cuits, but they are of opposite polarities and cannot be  
paralleled.  
CABLE INSTALLATION  
Install the welding cables to your Ranger 250 as fol-  
lows.  
STANDBY POWER CONNECTIONS  
1. The engine must be OFF to install welding cables.  
2. Remove the flanged nuts from the output terminals.  
The Ranger 250 is suitable for temporary, standby or  
emergency power using the engine manufacturer’s rec-  
ommended maintenance schedule.  
3. Connect the electrode holder and work cables to  
the weld output terminals. The terminals are iden-  
tified on the case front.  
The Ranger 250 can be permanently installed as a  
standby power unit for 240 VAC, three-wire, single-  
phase, 35 amp service. Connections must be made by  
a licensed electrician who can determine how the  
120/240 VAC power can be adapted to the particular  
installation and comply with all applicable electrical  
codes. The following information can be used as a  
guide by the electrician for most applications. Refer to  
the connection diagram in Figure A-2.  
4. Tighten the flanged nuts securely.  
5. Be certain that the metal piece you are welding (the  
“work”) is properly connected to the work clamp  
and cable.  
6. Check and tighten the connections periodically.  
1. Install the double-pole, double-throw switch  
between the power company meter and the  
premises disconnect. Switch rating must be the  
same or greater than the customer’s premises dis-  
connect and service over current protection.  
CAUTION  
• Loose connections will cause the output terminals to  
overheat. The terminals may eventually melt.  
• Do not cross the welding cables at the output termi-  
nal connection. Keep the cables isolated and sepa-  
rate from one another.  
2. Take necessary steps to assure load is limited to  
the capacity of the Ranger 250 by installing a 35  
amp, 240 VAC double-pole circuit breaker.  
Maximum rated load for each leg of the 240 VAC  
auxiliary is 33 amperes. Loading above the rated  
output will reduce output voltage below the allow-  
able ±10% of rated voltage, which may damage  
appliances or other motor-driven equipment and  
may result in overheating of the Ranger 250 engine  
and/or alternator windings.  
AUXILIARY POWER RECEPTACLES  
The auxiliary power of the Ranger 250 consists of two  
20 amp-120 VAC (5-20R) duplex receptacles and one  
50 amp 120/240 VAC (14-50R) receptacle. The 240  
VAC receptacle can be split for single-phase 120 VAC  
operation.  
3. Install a 50 amp, 120/240 VAC plug (NEMA Type  
14-50) to the double-pole circuit breaker using No.  
6, 4-conductor cable of the desired length. (The 50  
amp, 120/240 VAC plug is available in the optional  
K802R plug kit or as part number T12153-9.)  
The auxiliary power capacity is 8,000 watts of 60 Hz,  
single-phase power. The auxiliary power capacity rat-  
ing in watts is equivalent to volt-amperes at unity power  
factor. The maximum permissible current of the 240  
VAC output is 33 amps. The 240 VAC output can be  
split to provide two separate 120 VAC outputs with a  
maximum permissible current of 33 amps per output to  
4. Plug this cable into the 50 amp, 120/240 VAC  
receptacle on the Ranger 250 case front.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-8  
A-8  
INSTALLATION  
FIGURE A.2 – CONNECTION OF THE RANGER 250 TO PREMISES WIRING  
240 VOLT  
GROUNDED CONDUCTOR  
POWER  
COMPANY  
METER  
240 Volt  
120 VOLT  
60 Hz.  
3-Wire  
Service  
120 VOLT  
NEUTRAL  
BUS  
N
LOAD  
DOUBLE POLE DOUBLE THROW  
SWITCH RATING TO BE THE SAME  
AS OR GREATER THAN PREMISES  
SERVICE OVERCURRENT  
PROTECTION.  
PREMISES  
DISCONNECT AND  
SERVICE  
OVERCURRENT  
PROTECTION  
GROUND  
35AMP  
240 VOLT  
DOUBLE  
POLE  
CIRCUIT  
BREAKER  
50 AMP, 120/240  
VOLT PLUG  
NEMA TYPE 14-50  
240 VOLT  
GND  
N
50 AMP, 120/240 VOLT  
RECEPTACLE  
NOTE: No. 8 COPPER CONDUCTOR CABLE SEE  
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE  
SIZE RECOMMENDATIONS.  
WARNING  
• Only a licensed, certified, trained electrician should install the machine to a premises or residential elec-  
trical system. Be certain that:  
• The installation complies with the National Electrical Code and all other applicable electrical codes.  
• The premises is isolated and no feedback into the utility system can occur. Certain state and local laws  
require the premises to be isolated before the generator is linked to the premises. Check your state and  
local requirements.  
• A double-pole, double-throw transfer switch in conjunction with the properly rated double-throw circuit  
breaker is connected between the generator power and the utility meter.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Section B-1  
Section B-1  
TABLE OF CONTENTS  
- OPERATION SECTION -  
Operation...............................................................................................................................Section B  
Operating Instructions.................................................................................................................B-2  
Safety Instructions.......................................................................................................................B-2  
General Description ....................................................................................................................B-2  
Design Features..........................................................................................................................B-3  
Controls and Settings..................................................................................................................B-3  
Engine Controls ....................................................................................................................B-4  
Welding Controls ..................................................................................................................B-5  
Engine Operation ........................................................................................................................B-5  
Before Starting the Engine ...................................................................................................B-5  
Starting the Engine...............................................................................................................B-6  
Stopping the Engine .............................................................................................................B-6  
Welder Operation........................................................................................................................B-7  
General Operation ................................................................................................................B-7  
Stick Welding........................................................................................................................B-8  
Constant Current (CC-Stick) Welding.............................................................................B-8  
Pipe Welding...................................................................................................................B-8  
TIG Welding..........................................................................................................................B-9  
Wire Welding-CV ..................................................................................................................B-9  
Arc Gouging..........................................................................................................................B-9  
Auxiliary Power ...........................................................................................................................B-9  
Simultaneous Welding and Auxiliary Power Loads ............................................................B-10  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-2  
B-2  
OPERATION  
WARNING  
OPERATING INSTRUCTIONS  
Read and understand this entire section before operat-  
ing your Ranger 250.  
ENGINE EXHAUST can kill.  
• Use in open, well ventilated areas or  
vent exhaust to the outside.  
SAFETY INSTRUCTIONS  
WARNING  
• Do not stack anything on or near the  
engine.  
Do not attempt to use this equipment until you have  
thoroughly read all the operating and maintenance  
manuals supplied with your machine. They include  
important safety precautions; detailed engine starting,  
operating and maintenance instructions and parts lists.  
MOVING PARTS can injure.  
• Do not operate this equipment with any  
of its doors open or guards off.  
• Stop the engine before servicing it.  
• Keep away from moving parts.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts such  
as output terminals or internal wiring.  
Only qualified personnel should install, use, or ser-  
vice this equipment.  
• Insulate yourself from the work and  
ground.  
• Always wear dry insulating gloves.  
ADDITIONAL SAFETY PRECAUTIONS  
FUMES AND GASES can be dan-  
gerous.  
Always operate the welder with the hinged door closed  
and the side panels in place. These provide maximum  
protection from moving parts and insure proper cooling  
air flow.  
• Keep your head out of fumes.  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
GENERAL DESCRIPTION  
The Ranger 250 is a gasoline-engine-powered DC  
multi-process welding power source and 120 / 240  
VAC power generator. The engine drives a generator  
that supplies three-phase power for the DC welding cir-  
cuit and single-phase power for the AC auxiliary out-  
lets. The DC welding control system uses state of the  
art Chopper Technology (CT™) for superior welding  
performance.  
WELDING SPARKS can cause  
fire or explosion.  
• Keep flammable material away.  
• Do not weld on containers that have held  
combustibles.  
ARC RAYS can burn.  
• Wear eye, ear, and body protection.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-3  
B-3  
OPERATION  
• Longer engine life, reduced noise emissions and  
greater fuel economy with the automatic engine idler.  
DESIGN FEATURES  
• Single, full-range output control dial.  
• Conveniently located engine maintenance label  
under top engine door.  
• 4 welding modes: CC-stick, downhill stick welding on  
pipe, CV wire welding and Touch-Start TIG™ (elimi-  
nates high frequency and tungsten contamination).  
• Engine hour meter for scheduled maintenance.  
• Automatic engine shutdown protection for low oil  
pressure.  
• Output at welding terminals controlled by electronic  
contactor. Can be switched to “On”, or to “Remotely  
Controlled”. Contactor auto-activated when con-  
nected. 6-pin connector for remote output.  
• Electric start. Reduce abnormal charging thanks to  
a backlit battery charger system light indicator.  
• Many wire feeder combinations: 14-pin connector for  
Lincoln wire feeders LN-25, LN-23P, LN-7, LN-8  
operates when using a Lincoln wire feeder with the  
appropriate control cable.  
• Oil drain valve (no tools required).  
• 8,000 watts of continuous duty AC generator power.  
• Up to 33 amps at 240V from the 120V/240V recep-  
tacle. Circuit breaker protection.  
• Smart machine! Remote operation and Magnum®  
spool gun; 42VAC for LN-742 and Cobramatic® wire  
feeders.  
• Two 120V 20A duplex receptacles. Circuit breaker  
protection. Will operate up to a 9” grinder.  
• Wire feed voltmeter switch matches polarity of wire  
feeder voltmeter to polarity of electrode.  
CONTROLS AND SETTINGS  
• 12 gallon fuel capacity allows you to run an extend-  
ed day.  
The gasoline engine stop/start and idler controls are  
located on the case front panel. The welder controls are  
also located here. See Figure B.1.  
• Easily check fuel level during operation and refu-  
elling with highly visible fuel gauge located next to  
the fuel cap on case top side.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-4  
B-4  
OPERATION  
FIGURE B.1 – CASE FRONT PANEL CONTROLS  
1
6
G3668 VM  
K
NO.- CODE SERIAL NO.  
-
CHOKE  
START  
HIGH  
AUTO  
RUN  
Hobbs  
QUARTZ  
IDLER  
0
0
0
0
0
0
HOURS  
4
3
STOP  
OUTPUT  
22 CV  
155 CC  
20 CV  
120 CC  
24 CV  
190 CC  
17 CV  
85 CC  
26 CV  
220 CC  
14 CV  
50 CC  
12 CV  
20 CC  
NRTL/C  
28 CV  
250 CC  
NEUTRAL GROUND TO FRAME  
THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA  
2
WELD MODE  
ARC CONTROL  
-4  
7
0
+2  
+4  
-2  
WELD WIRE FEEDER  
TERMINALS ON VOLTMETER  
CV-WIRE  
PIPE  
5
+6  
+8  
-6  
-8  
CC-STICK  
TOUCH START TIG  
REMOTELY  
CONTROLLED  
+10  
SOFT -10  
CRISP  
13  
8
9
12  
11  
CIRCUIT  
BREAKERS  
120/240 V  
120 V  
SIMULTANEOUS WELDING AND POWER  
AUX. POWER  
WATTS  
240 V. RECEPTACLE  
AMPS  
WELD CURRENT  
AMPS  
0
33  
21  
13  
6
8000  
5000  
3000  
1500  
0
100  
150  
200  
250  
10  
0
AUXILIARY POWER RATING  
WELDER OUTPUT RATING  
WATTS  
8,000  
DUTY CYCLE  
VOLTS  
AMPS  
DUTY CYCLE  
VOLTS  
100%  
120/240  
250 DC  
100%  
25  
AVAILABLE POWER IS REDUCED WHILE WELDING  
SINGLE PHASE 60 HZ  
80V MAX OCV AT RATED 3700 RPM  
receptacles (approximately 100 watts mini-  
mum), the engine accelerates and operates  
at high speed.  
ENGINE CONTROLS  
1. RUN/STOP SWITCH: RUN position energizes the  
engine prior to starting. STOP position stops the  
engine. The oil pressure interlock switch prevents  
battery drain if the switch is left in the RUN position  
and the engine is not operating.  
c. When welding ceases or the AC power load  
is turned off, a fixed time delay of approxi-  
mately 12 seconds starts. If the welding or  
AC power load is not restarted before the  
end of the time delay, the idler reduces the  
engine speed to low idle speed.  
2. CHOKE: When pulled out, it closes the choke valve  
on the engine carburetor for quick starting.  
3. START PUSHBUTTON: Energizes the starter  
d. The engine will automatically return to high  
idle speed when the welding load or AC  
power load is reapplied.  
motor to crank the engine.  
4. IDLER SWITCH: Has two positions as follows:  
5. ENGINE ALTERNATOR TROUBLE LIGHT: The  
yellow engine alternator light is off when the battery  
charging system is functioning normally. If the light  
turns on, the alternator or the voltage regulator may  
not be operating correctly. The light may also come  
on if the battery is not holding a charge. It is normal  
for the light to come on while starting the engine.  
A) In the HIGH position, the engine runs at the high  
idle speed controlled by the engine governor.  
B) In the AUTO position, the idler operates as fol-  
lows:  
a. When switched from HIGH to AUTO or after  
starting the engine, the engine will operate  
at high speed for approximately 12 seconds  
and then go to low idle speed.  
6. ENGINE HOUR METER: Displays the total time  
that the engine has been running. This meter is  
useful for scheduling prescribed maintenance.  
b. When the electrode touches the work or  
power is drawn from the auxiliary power  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-5  
B-5  
OPERATION  
12. WELD TERMINALS CONTROL SWITCH: In the  
WELD TERMINALS ON position, the weld output  
is electrically hot all the time. In the REMOTELY  
CONTROLLED position, the weld output is con-  
trolled by a wire feeder or amptrol device, and is  
electrically off until a remote switch is depressed.  
WELDING CONTROLS  
7. OUTPUT CONTROL: The OUTPUT dial provides  
continuous control of the welding current or weld-  
ing voltage depending on the selected welding  
mode. This control is not active in the CC-STICK,  
PIPE, and CV-WIRE modes when a remote con-  
trol or wire feeder with remote control is connect-  
ed to either the 6-pin or 14-pin Amphenol.  
13. WIRE FEEDER VOLTMETER SWITCH: Matches  
the polarity of the wire feeder voltmeter to the  
polarity of the electrode.  
8. WELD MODE SELECTOR SWITCH: This switch  
provides four selectable welding modes:  
• CV-WIRE  
• PIPE  
• CC-STICK  
• TOUCH START TIG  
ENGINE OPERATION  
WARNING  
DO NOT RUN THE ENGINE AT EXCESSIVE  
SPEEDS. The maximum allowable high idle speed for  
the Ranger 250 is 3750 RPM, no load. Do NOT adjust  
the governor screw on the engine. Severe personal  
injury and damage to the machine can result if it is  
operated at speeds above the maximum rated speed.  
9. ARC CONTROL: The ARC CONTROL WIRE/  
STICK dial is active in the CV-WIRE and CC-  
STICK modes, and has different functions in  
these modes. This control is not active in the TIG  
and PIPE modes.  
Read and understand all safety instructions included in  
the engine operator’s manual that is shipped with your  
Ranger 250.  
CC-STICK mode: In this mode, the ARC CON-  
TROL sets the short circuit current during stick  
welding (arc-force). Increasing the number from  
-10 to +10 increases the short circuit current and  
prevents sticking of the electrode to the plate  
while welding. This can also increase spatter. It  
is recommended that the ARC CONTROL be set  
to the minimum number without electrode stick-  
ing. Start with a setting at 0.  
BEFORE STARTING THE ENGINE  
Check and fill the engine oil level:  
1. Be sure the machine is on a level surface.  
2. Open top engine door and remove the engine oil  
dipstick and wipe it with a clean cloth. Reinsert the  
dipstick and check the level on the dipstick.  
CV-WIRE mode: In this mode, turning the ARC  
CONTROL clockwise from -10 (soft) to +10 (crisp)  
changes the arc from soft and washed-in to crisp  
and narrow. It acts as an inductance control. The  
proper setting depends on the procedure and  
operator preference. Start with a setting at 0.  
3. Add oil (if necessary) to bring the level up to the full  
mark. Do not overfill. Close engine door.  
4. See the Maintenance section for specific oil rec-  
ommendations.  
10. 14-PIN AMPHENOL: For attaching wire feeder  
control cables to the Ranger 250. Includes con-  
tactor closure circuit, auto-sensing remote control  
circuit, and 120V and 42V power. The remote  
control circuit operates the same as the 6-pin  
Amphenol. See below.  
Check and fill the engine fuel tank:  
WARNING  
11. 6-PIN AMPHENOL: For attaching optional  
remote control equipment. When in the CC-  
STICK, PIPE, and CV-WIRE modes and when a  
remote control is connected to the Amphenol, the  
auto-sensing circuit in the Ranger 250 automati-  
cally switches the OUTPUT control from control at  
the welder to remote control.  
GASOLINE can cause fire or  
explosion.  
• Stop engine when fueling.  
• Do not smoke when fueling.  
• Do not overfill tank.  
• Avoid contact with skin or breathing of vapor.  
• Keep sparks and flame away from tank.  
When using the TOUCH START TIG mode, the  
OUTPUT control on the front of the Ranger 250  
sets the maximum current range.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-6  
B-6  
OPERATION  
1. Remove the fuel tank cap.  
NOTE: Starting a Ranger 250 for the first time, or after  
an extended period of time of not operating, will take  
longer than normal. The fuel pump has to fill the fuel  
line and carburetor. If the engine will not start, see the  
Troubleshooting section of this manual.  
2. Fill the tank approximately 4 inches (100mm) from  
the top of the filler neck to allow for fuel expansion.  
(Observe the fuel gauge while filling.) DO NOT  
FILL THE TANK TO THE POINT OF OVERFLOW.  
3. Replace the fuel cap and tighten securely.  
STOPPING THE ENGINE  
4. See the Maintenance section for specific fuel rec-  
1. Remove all welding and auxiliary power loads and  
allow the engine to run at low idle speed for a few  
minutes to cool the engine.  
ommendations.  
STARTING THE ENGINE  
2. Stop the engine by placing the RUN-STOP switch in  
the STOP position.  
1. Remove all plugs connected to the AC power  
receptacles.  
NOTE: A fuel shut off valve is not required on the  
Ranger 250 because the fuel tank is mounted below  
the engine.  
2. Set the IDLER switch to AUTO.  
/
3. Set the RUN/STOP switch to RUN.  
4. Pull the choke to the full out position.  
BREAK-IN PERIOD  
5. Press and hold the engine START button until the  
engine starts.  
Any engine will use a small amount of oil during its  
“break-in” period. For the gasoline engine on the  
Ranger 250, break-in is about 50 running hours.  
6. Release the engine START button when the  
engine starts.  
Check the oil at least twice a day during break-in.  
Change the oil after the first 25 hours of operation.  
Change the oil filter at the second oil change. For more  
details, see the Maintenance section of this manual.  
7. Push the choke back in.  
8. The engine will run at high idle speed for approx-  
imately 12 seconds and then go to low idle speed.  
Allow the engine to warm up at low idle for sever-  
al minutes before applying a load and/or switch-  
ing to high idle. Allow a longer warm up time in  
cold weather.  
CAUTION  
During break-in, subject the Ranger 250 to moderate  
loads. Avoid long periods running at idle. Before stop-  
ping the engine, remove all loads and allow the engine  
to cool several minutes.  
CAUTION  
Operating the starter motor for more than 5 seconds  
can damage the motor. If the engine fails to start,  
release the START button and wait 10 seconds before  
activating 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.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-7  
B-7  
OPERATION  
The Ranger 250 can deliver from 40 to 250 amps of  
constant current for DC stick welding or from 20 to 250  
amps of constant voltage current for DC semiautomat-  
ic wire feed welding. DC TIG welding is possible  
across the entire range from 20 to maximum rated out-  
put. Output can be adjusted by setting the OUTPUT  
control dial and the ARC control dial on the output con-  
trol panel to the settings that are best for your selected  
welding process.  
WELDER OPERATION  
GENERAL INFORMATION  
WARNING  
• Do not touch electrically live parts or elec-  
trodes with your skin or wet clothing.  
NOTE: An unstable or unsatisfactory welding arc can  
result if welding cables are too long or are coiled on the  
machine when welding. See Table A.1 in the  
Installation section. Straighten out coiled cables  
before welding.  
• Do not breathe welding fumes or gases.  
• Use ventilation or exhaust to remove weld-  
ing from the breathing area.  
• Keep flammable material away.  
• Wear eye, ear, and body protection.  
TABLE B.1 – TYPICAL RANGER 250 FUEL CONSUMPTION  
Onan P216  
16 hp @ 3600 rpm  
gal./hr (liters/hr)  
Kohler CH20  
12 gallons-hours  
gal./hr (liters/hr)  
Running Time for  
12 gallons-hours  
Onan/Kohler  
Low Idle - No Load  
2400 R.P.M.  
0.6 (2.3)  
0.8 (3.0)  
1.7 (6.4)  
1.8 (6.8)  
0.6 (2.3)  
0.8 (3.0)  
1.4 (5.3)  
1.4 (5.3)  
20/20  
15/15  
High Idle - No Load  
3700 R.P.M.  
DC Weld Output  
250 Amps @ 25 Volts  
7.0/8.6  
6.4/8.6  
Auxiliary Power  
8,000 Watts  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-8  
B-8  
OPERATION  
The ARC control sets the short circuit current during  
stick welding (arc-force). Increasing the number from  
-10 to +10 increases the short circuit current and pre-  
vents sticking of the electrode to the plate while weld-  
ing. This can also increase spatter. It is recommended  
that the ARC control be set to the minimum number  
without electrode sticking. Start with the dial set at 0.  
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  
PIPE 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. The  
OUTPUT control adjusts the full output range for stick  
welding.  
This slope-controlled setting is intended for “out-of-  
position” and “downhill” pipe welding where the opera-  
tor would like to control the current level by changing  
the arc length. The OUTPUT control dial adjusts the full  
output range for pipe welding. The ARC control is not  
active in the PIPE mode.  
1
2
TABLE B.2 – TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES  
DCEN (-)  
DCEP (+)  
Approximate Argon Gas Flow Rate  
C.F.H. (l/min.)  
Tungsten  
Electrode  
Diameter  
in. (mm)  
TIG TORCH  
Nozzle  
1%, 2%  
Thoriated  
Tungsten  
1%, 2%  
Thoriated  
Tungsten  
Aluminum  
Stainless Steel  
4, 5  
Size  
3
3
3
0 .010 (.25)  
2-15  
5-20  
15-80  
3-8  
5-10  
5-10  
(2-4)  
(3-5)  
(3-5)  
3-8  
5-10  
5-10  
(2-4)  
(3-5)  
(3-5)  
#4, #5, #6  
0.020  
0.040  
(.50)  
(1.0)  
1/16  
(1.6)  
70-150  
10-20  
5-10  
(3-5)  
9-13  
(4-6)  
#5, #6  
3/32  
1/8  
(2.4)  
(3.2)  
150-250  
250-400  
15-30  
25-40  
13-17 (6-8)  
15-23 (7-11)  
11-15 (5-7)  
11-15 (5-7)  
#6, #7, #8  
5/32  
3/16  
1/4  
(4.0)  
(4.8)  
(6.4)  
400-500  
500-750  
750-1000  
40-55  
55-80  
180-125  
21-25 (10-12) 13-17 (6-8)  
23-27 (11-13) 18-22 (8-10)  
28-32 (13-15) 23-27 (11-13)  
#8, #10  
1
When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shield-  
ing gases.  
2 Tungsten electrodes are classified as follows by the American Welding Society (AWS):  
Pure  
EWP  
1% Thoriated  
2% Thoriated  
EWTh-1  
EWTh-2  
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated  
Tungsten in AC and DC applications.  
3
DCEP is not commonly used in these sizes.  
4 TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:  
# 4 = 1/4 in. (6 mm)  
# 5 = 5/16 in. (8 mm)  
# 6 = 3/8 in. (10 mm)  
# 7 = 7/16 in. (11 mm)  
# 8 = 1/2 in. (12.5 mm)  
#10 = 5/8 in. (16 mm)  
5 TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are  
less prone to breakage, but cannot withstand high temperatures and high duty cycles.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-9  
B-9  
OPERATION  
Some recommended solid wires for MIG welding are:  
.035 (0.9 mm), and .045 (1.1 mm), L-50 and L-56, .035  
(0.9 mm) and .045 (1.1 mm) Blue Max MIG 308 LS.  
TIG WELDING  
The TOUCH START TIG setting of the MODE switch is  
for DC TIG (Tungsten Inert Gas) welding. To initiate a  
weld, the OUTPUT control is first set to the desired cur-  
rent and the tungsten is touched to the work. During  
the time the tungsten is touching the work there is very  
little voltage or current and, in general, no tungsten  
contamination. Then the tungsten is gently lifted off the  
work in a rocking motion, which establishes the arc.  
For any electrodes, including those above, the proce-  
dures should be kept within the rating of the machine.  
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.  
The ARC CONTROL is not active in the TIG mode.  
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. If desired, the K930-2 TIG  
Module can be used with the Ranger 250. The follow-  
ing settings are for reference.  
Set the OUTPUT CONTROL to adjust output current to  
the desired level for the gouging electrode being used  
according to the ratings in Table B.3.  
TABLE B.3 – CURRENT RANGE  
PER ELECTRODE DIAMETER  
Ranger 250 settings when using the K930-2 TIG  
Module with an Amptrol or Arc Start Switch:  
Electrode  
Diameter  
Current Range  
(DC, Electrode Positive)  
a. Set the MODE Switch to the TOUCH START TIG  
setting.  
1/8"  
5/32"  
3/16"  
30-60 Amps  
90-150 Amps  
150-200 Amps  
b. Set the “IDLER” Switch to the “AUTO” position.  
c. Set the "WELD TERMINALS” switch to the  
“REMOTELY CONTROLLED” position. This will  
keep the solid state contactor open and provide a  
“cold” electrode until the Amptrol or Arc Start switch  
is pressed.  
AUXILIARY POWER  
WARNING  
When using the TIG Module, the OUTPUT control on  
the Ranger 250 is used to set the maximum range of  
the CURRENT.  
Be sure that any electrical equipment plugged into the  
generator AC power receptacles can withstand a ±10%  
voltage and a ±3% frequency variation.  
WIRE WELDING-CV  
Connect a wire feeder to the Ranger 250 according to  
the instructions in the Accessories section.  
Start the engine and set the IDLER control switch to  
the desired operating mode. Full power is available  
regardless of the welding control settings as long as no  
welding current is being drawn.  
In the CV-WIRE mode, the Ranger 250 can be used  
with a broad range of flux cored wire (Innershield and  
Outershield) electrodes and solid wires for MIG weld-  
ing (gas metal arc welding). Welding can be finely  
tuned using the ARC CONTROL. Turning the ARC  
CONTROL clockwise from -10 (soft) to +10 (crisp)  
changes the arc from soft and washed-in to crisp and  
narrow. It acts as an inductance control. The proper  
setting depends on the procedure and operator prefer-  
ence. Start with the dial set at 0.  
The auxiliary power of the Ranger 250 consists of two  
20 amp-120 VAC (5-20R) duplex receptacles and one  
50 amp 120/240 VAC (14-50R) receptacle. The 240  
VAC receptacle can be split for single-phase 120 VAC  
operation.  
The auxiliary power capacity is 8,000 watts of 60 Hz,  
single-phase power. The auxiliary power capacity rat-  
ing in watts is equivalent to volt-amperes at unity power  
factor. The maximum permissible current of the 240  
VAC output is 33 amps.  
Some recommended Innershield electrodes are:  
NR-311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H.  
Recommended Outershield electrodes are: 0S-70,  
0S-71M.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-10  
B-10  
OPERATION  
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 amp  
branch circuits. (These circuits cannot be paralleled.)  
Output voltage is within ±10% at all loads up to rated  
capacity.  
NOTE: The 240 VAC receptacle has two circuits, each  
of which measures 120 VAC to neutral. However, they  
are of opposite polarity and cannot be paralleled.  
SIMULTANEOUS WELDING AND  
AUXILIARY POWER LOADS  
The 120 VAC auxiliary power receptacles should only  
be used with three-wire, grounded type plugs or  
approved double-insulated tools with two-wire plugs.  
The current rating of any plug used with the system  
must be at least equal to the current capacity of the  
associated receptacle. For extension cord lengths, see  
Table B.5.  
The auxiliary power ratings are with no welding load.  
Simultaneous welding and power loads are specified in  
Table B.4. The permissible currents shown assume  
that current is being drawn from either the 120 VAC or  
240 VAC supply (not both at the same time).  
TABLE B.4 – RANGER 250 SIMULTANEOUS WELDING AND POWER LOADS  
Permissible Auxiliary  
Current in Amps  
Welding  
Output- Amps  
Permissible Power-Watts  
(Unity Power Factor)  
@ 120 VAC*  
40*  
@ 240 VAC**  
33  
0
8000  
5000  
3000  
1500  
0
100  
150  
200  
250  
40*  
25  
21  
12.5  
6.3  
0
12.5  
0
* Each duplex receptacle is limited to 20 amps.  
** Not to exceed 25 amps per 120 VAC branch circuit when splitting the 240 VAC output.  
TABLE B.5 – RANGER 250 EXTENSION CORD LENGTH RECOMMENDATIONS  
(Use the shortest length extension cord possible sized per the following table)  
Current Voltage  
Maximum Allowable Cord Length in Ft. (m) for Conductor Size  
12 AWG 10 AWG 8 AWG 6 AWG  
75 125 175  
Load  
(Watts)  
(Amps) (Volts)  
14 AWG  
4 AWG  
15  
20  
15  
20  
33  
120  
120  
240  
240  
240  
1800  
2400  
3600  
4800  
8000  
30  
(9)  
40  
(12)  
(9)  
(23)  
(15)  
(46)  
(30)  
(18)  
(38)  
(27)  
(69)  
(53)  
(30)  
(53)  
(42)  
(107)  
(84)  
(53)  
300  
(91)  
(69)  
30  
75  
60  
50  
150  
100  
60  
88  
138  
350  
275  
175  
225  
600  
450  
250  
60  
(18)  
(23)  
(18)  
225  
175  
100  
(183)  
(137)  
(76)  
Conductor size is based on maximum 2.0% voltage drop.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Section C-1  
Section C-1  
TABLE OF CONTENTS  
- ACCESSORIES -  
Accessories ..........................................................................................................................Section C  
Options/Accessories ...................................................................................................................C-2  
Field Installed Options .........................................................................................................C-2  
TIG Welding Accessories .....................................................................................................C-2  
Semiautomatic FCAW and MIG Welding Accessories.........................................................C-2  
Connection of Lincoln Electric Wire Feeders .......................................................................C-3  
Connection of the K867 Universal Adapter....................................................................C-3  
Connection of the LN-25 “Across the Arc” .....................................................................C-4  
Connection of the LN-25 with 42V Remote Output Control Module..............................C-5  
Connection of the LN-25 with K857 Remote Control.....................................................C-6  
Connection of the LN-7 Using the K584 Control Cable .................................................C-7  
Connection of the LN-8 Using the K595 Control Cable .................................................C-8  
Connection of the LN-742 ..............................................................................................C-9  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-2  
C-2  
ACCESSORIES  
plugs rated at 15 amps each and one dual voltage, full  
KVA plug rated at 120/240 volts, 50 amps.  
OPTIONS/ACCESSORIES  
T12153-9 50 AMP, 120/240V POWER PLUG -  
Provides one dual voltage plug for full KVA power.  
FIELD INSTALLED OPTIONS  
The following options/accessories are available for  
your Ranger 250 from your local Lincoln distributor.  
TIG WELDING ACCESSORIES  
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.)  
K1783-9 TIG TORCH - For TIG welding with shielding  
gas. Includes 25 feet of cable.  
K963-2 - Hand Amptrol.  
K870 - Foot Amptrol.  
K1737-1 FOUR-WHEEL ALL-TERRAIN UNDERCAR-  
RIAGE - For moving by hand.  
NOTE: TIG welding requires a Magnum™ TIG Gun,  
appropriate Magnum Parts Kit and argon gas.  
K1770-1 UNDERCARRIAGE (FACTORY) - For mov-  
ing by hand on a smooth surface. One or two gas  
cylinders can be mounted on the rear of the undercar-  
riage with the installation of K1745-1 Cylinder  
Holder(s).  
SEMIAUTOMATIC FCAW AND MIG  
WELDING ACCESSORIES  
LN-25 WIRE FEEDER K449 - This portable unit pro-  
vides CC/CV for flux-cored arc welding (FCAW) and  
metal inert gas welding (MIG). Includes a gas solenoid  
and an internal contactor that allows across-the-arc  
operation with no control cable. The LN-25 provides a  
“cold” electrode until the gun trigger is pressed. For  
voltage control at the feeder, a K444-1 Remote Voltage  
Control Kit or K857 Remote Control is required. Refer  
to connection instructions later in this section.  
K1739-1 CABLE CARRIER KIT - For use on K1737-1  
and K1770-1 Undercarriages.  
K1745-1 SINGLE GAS CYLINDER HOLDER - For use  
on K1770-1 Undercarriage. One or two may be  
installed on an undercarriage.  
K1788-1 ROLL CAGE - Gives added damage protec-  
tion.  
LN-7 OR LN-8 WIRE FEEDER - Semiautomatic, con-  
stant speed wire feeders.  
K886-2 CANVAS COVER - Protects machine when  
not in use.  
NOTE: Gas-shielded welding requires a Magnum Gun.  
Gasless welding requires an Innershield Gun.  
S24647 SPARK ARRESTER - Mounts inside exhaust  
pipe.  
LN-742 WIRE FEEDER - A semiautomatic wire feeder  
with “cold” electrode. Refer to connection instructions  
later in this section.  
K702 ACCESSORY KIT - Accessory set includes 35 ft.  
(10.7 meters) 2 AWG electrode cable, 30 ft. (9.1  
meters) 2 AWG work cable, headshield with No. 12 fil-  
ter, GC300 work clamp and Cooltong 300 electrode  
holder. Cables are rated at 250 amps, 40% duty cycle.  
MAGNUM SPOOL GUN (K487-25) - A lightweight,  
semiautomatic wire feeder for aluminum welding with  
argon gas. Has built-in remote wire speed control in  
the handle. Requires the K488 SG Control Module.  
Refer to connection instructions later in this section.  
K857 28 ft. (8.5m) or K857-1 100 ft. (30.4m)  
REMOTE CONTROL - 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.  
SG CONTROL MODULE (K488) - Controls wire speed  
and gas flow. Provides the required control interface  
between the Ranger 250 and the K487-25 Magnum  
Spool Gun. Requires the K691-10 Input Cable.  
K1690-1 GFCI RECEPTACLE KIT - Includes one UL  
approved 120 volt ground fault circuit interrupter duplex  
type receptacle with cover and installation instructions.  
Replaces the factory installed 120V duplex receptacle.  
Each receptacle of the GFCI Duplex is rated at 20  
amps. The maximum total current from the GFCI  
Duplex is limited to 20 amps. Two kits are required.  
K444-1 REMOTE VOLTAGE CONTROL - Provides  
voltage adjustment control at the feeder. Includes 25  
feet of cable.  
K126-2 INNERSHIELD GUN - For gasless welding.  
Includes 15 feet of cable.  
K470-2 MAGNUM GUN CONNECTOR KIT - For gas-  
K802-N POWER PLUG KIT - Provides four 120 volt  
plugs rated at 20 amps each and one dual voltage, full  
KVA plug rated at 120/240 volts, 50 amps.  
shielded welding.  
K466-1 MAGNUM GUN CONNECTOR KIT - For con-  
necting the Magnum 300 MIG Gun to the feeder for  
gas-shielded welding.  
K802-R POWER PLUG KIT - Provides four 120 volt  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-3  
C-3  
ACCESSORIES  
3. Connect the K867 Universal Adapter to the 14-pin  
amphenol of the Ranger 250 as shown in Figure  
C.1. Make the proper connections for local or  
remote control according to Figure C.1 and the fol-  
lowing NOTES, indicated on the figure:  
CONNECTION OF LINCOLN  
ELECTRIC WIRE FEEDERS  
WARNING  
A. These leads are not used for the Ranger 250.  
Insulate each unused lead individually.  
ELECTRIC SHOCK can kill.  
• Do not operate with panels open.  
B. For wire feeders that return a signal for welding  
output, use an isolation relay to close leads 2  
and 4.  
• Disconnect NEGATIVE (-) BATTERY  
LEAD before servicing.  
• Do not touch electrically live parts.  
MOVING PARTS can injure.  
C. Refer to the Operation section of this manual  
• Keep guards in place.  
for maximum wire feeder auxiliary current draw.  
• Keep away from moving parts.  
4. Set the “MODE” switch to the “CV-WIRE” position.  
5. Place the “IDLER” switch in the “AUTO” position.  
• Only qualified personnel should install,  
use or service this equipment.  
CAUTION  
CONNECTION OF THE RANGER 250 TO  
WIRE FEEDERS USING K867 UNIVERSAL  
ADAPTER (SEE FIGURE C.1)  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control cir-  
cuits may be damaged. The engine governor setting is  
preset at the factory – do not adjust above RPM spec-  
ifications listed in this manual.  
NOTE: When you use the Ranger 250 with non-Lincoln  
Electric wire feeders or with certain earlier models of  
Lincoln wire feeders, you will require the K867  
Universal Adapter. The following discussion and con-  
nection diagram explain in general how to make the  
proper connections.  
6. Set the “VOLTMETER” switch to “+” or “-” depend-  
ing on the polarity chosen.  
1. Shut the welder off.  
7. Set the ARC control to “0” initially and adjust to suit.  
8. Adjust wire feed speed at the wire feeder.  
2. Connect the electrode cable from the wire feeder to  
the “+” terminal of the welder. Connect the work  
cable to the “-” terminal of the welder.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
FIGURE C.1 – RANGER 250/K867 UNIVERSAL ADAPTER CONNECTION DIAGRAM  
14-PIN  
AMPHENOL  
A
K867 UNIVERSAL  
ADAPTER PLUG  
B
C
+
–
TO WORK  
ELECTRODE CABLE  
TO WIRE FEED UNIT  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-4  
C-4  
ACCESSORIES  
5. Attach the single lead from the LN-25 control box  
to the work using the spring clip on the end of the  
lead. This is only a control lead – it carries no  
welding current.  
CONNECTION OF THE LN-25 TO THE  
RANGER 250 “ACROSS THE ARC”  
(SEE FIGURE C.2.)  
1. Shut the welder off.  
6. Place the “IDLER” switch in the “AUTO” or “HIGH”  
position as desired.  
2. Connect the electrode cable from the LN-25 to the  
“-” terminal of the welder. Connect the work cable  
to the “+” terminal of the welder.  
CAUTION  
NOTE: Figure C.2 shows the electrode connected for  
negative polarity. To change polarity, shut the welder  
off and reverse the electrode and work cables at the  
Ranger 250 output terminals.  
If you are using an LN-25 without an internal contactor,  
the electrode will be “HOT” when the Ranger 250 is  
started.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
7. Place the “WELD TERMINALS” switch in the  
“WELD TERMINALS ON” position.  
3. Set the “VOLTMETER” switch to “+” or “-” depend-  
ing on the polarity chosen.  
8. Adjust wire feed speed at the LN-25 and adjust the  
welding voltage with the output “CONTROL” at the  
LN-25 if optional remote control kit is used.  
4. Set the “MODE” switch to the “CV-WIRE” position.  
9. Set the ARC control to “0” initially and adjust to suit.  
FIGURE C.2 – RANGER 250/LN-25 ACROSS THE ARC CONNECTION DIAGRAM  
-
-
+
–
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-5  
C-5  
ACCESSORIES  
5. Set the “MODE” switch to the “CV-WIRE” position.  
CONNECTION OF THE LN-25 TO THE  
RANGER 250 WITH 42 VOLT REMOTE  
OUTPUT CONTROL MODULE  
(SEE FIGURE C.3.)  
6. Place the “IDLER” switch to the “AUTO” or “HIGH”  
position as desired.  
CAUTION  
1. Shut the welder off.  
2. Connect the electrode cable from the K626-XX  
Input Cable Assembly to the “-” terminal of the  
welder and to the LN-25 Wire Feeder. Connect the  
work cable to the “+” terminal of the welder.  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control cir-  
cuits may be damaged. The engine governor setting is  
preset at the factory – do not adjust above RPM spec-  
ifications listed in this manual.  
NOTE: Figure C.3 shows the electrode connected for  
negative polarity. To change polarity, shut the welder  
off and reverse the electrode and work cables at the  
Ranger 250 output terminals.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
7. Place the “WELD TERMINALS” switch in the  
“REMOTELY CONTROLLED” position.  
3. Connect the input cable from the K626-XX Input  
Cable Assembly to the 14-pin amphenol on the  
Ranger 250 and the input cable plug on the LN-25.  
8. Adjust wire feed speed and voltage at the LN-25.  
9. Set the ARC control to “0” initially and adjust to suit.  
4. Set the “VOLTMETER” switch to “+” or “-” depend-  
ing on the polarity chosen.  
FIGURE C.3 – RANGER 250/LN-25 WITH  
42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM  
-
+
–
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-6  
C-6  
ACCESSORIES  
CONNECTION OF THE LN-25 TO THE  
RANGER 250 “ACROSS THE ARC”  
WITH K857 REMOTE CONTROL  
(SEE FIGURE C.4.)  
CAUTION  
If you are using an LN-25 without an internal contactor,  
the electrode will be “HOT” when the Ranger 250 is  
started.  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-25 to the  
“-” terminal of the welder. Connect the work cable  
to the “+” terminal of the welder.  
6. Set the “MODE” switch to “CV-WIRE.”  
7. Set the “WELD TERMINALS” switch to “WELD  
TERMINALS ON.”  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
8. Set the “VOLTMETER” switch to “+” or “-”  
depending on the polarity chosen.  
NOTE: Figure C.4 shows the electrode connected for  
negative polarity. To change polarity, shut the welder  
off and reverse the electrode and work cables at the  
Ranger 250 output terminals.  
9. Adjust wire feed speed at the LN-25 and adjust  
the welding voltage with the K857 if optional  
remote control is used.  
3. Connect the K857 Remote Control to the 6-pin  
amphenol on the Ranger 250.  
10. Adjust the “ARC” control to “0” initially and adjust  
to suit.  
4. Attach the single lead from the LN-25 to the work  
using the spring clip on the end of the lead. This is  
only a sense lead – it carries no welding current.  
5. Place the “IDLER” switch in the “AUTO” or “HIGH”  
position, as desired.  
FIGURE C.4 – RANGER 250/LN-25 ACROSS THE ARC  
CONNECTION DIAGRAM WITH K857 REMOTE CONTROL  
1 4 P IN  
-
AM P H E N O L  
-
6 P IN  
AM P H E N O L  
O P T IO N AL K 8 5 7  
R E M O T E C O N T R O L  
LN - 2 5  
W IR E F E E D E R  
+
–
W O R K C LIP LE AD  
T O W O R K  
T O W O R K  
E LE C T R O D E C AB LE  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-7  
C-7  
ACCESSORIES  
4. Set the “VOLTMETER” switch to “+” or “-” depend-  
ing on the polarity chosen.  
CONNECTION OF THE LN-7 TO THE  
RANGER 250 USING K584 CONTROL  
CABLE (SEE FIGURE C.5.)  
5. Set the “MODE” switch to the “CV-WIRE” position.  
6. Place the “IDLER” switch in the “HIGH” position.  
NOTE: If your LN-7 comes equipped with a K291 or  
K404 input cable, refer to CONNECTION OF THE LN-  
7 Using K867 UNIVERSAL ADAPTER, rather than this  
discussion, to connect your Ranger 250 for wire feed  
welding.  
CAUTION  
Any increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control cir-  
cuits may be damaged. The engine governor setting is  
preset at the factory – do not adjust above RPM spec-  
ifications listed in this manual.  
1. Shut the welder off.  
2. Connect the electrode cable from the K584-XX  
Control Cable to the “+” terminal of the welder and  
to the LN-7 wire feeder. Connect the work cable to  
the “-” terminal of the welder.  
NOTE: Figure C.5 shows the electrode connected for  
positive polarity. To change polarity, shut the welder off  
and reverse the electrode and work cables at the out-  
put terminals.  
7. Place the “WELD TERMINALS” switch in the  
“REMOTELY CONTROLLED” position.  
8. Adjust wire feed speed at the LN-7 and adjust the  
welding voltage with the optional remote control if  
used.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
3. Connect the input cable from the K584-XX Control  
Cable to the 14-pin amphenol on the Ranger 250  
and the input cable plug on the LN-7.  
9. Set the “ARC” control at “0” initially and adjust to  
suit.  
FIGURE C.5 – RANGER 250/LN-7 WITH 584 CONTROL CABLE CONNECTION DIAGRAM  
-
-
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-8  
C-8  
ACCESSORIES  
5. Place the IDLER switch in the “HIGH” position.  
CONNECTION OF THE LN-8 TO THE  
RANGER 250 USING K595 CONTROL  
CABLE (SEE FIGURE C.6.)  
CAUTION  
An increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control cir-  
cuits may be damaged. The engine governor setting is  
preset at the factory – do not adjust above RPM spec-  
ifications listed in this manual.  
NOTE: If your LN-8 comes equipped with a K291 or  
K404 input cable, refer to CONNECTION OF THE LN-  
7 Using K867 UNIVERSAL ADAPTER, rather than this  
discussion, to connect your Ranger 250 for wire feed  
welding.  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-8 to the  
“+” terminal of the welder. Connect the work cable  
to the “-” terminal of the welder.  
6. Set the “VOLTMETER” switch to “+” or “-” depend-  
ing on the polarity chosen.  
NOTE: Welding cable must be sized for current and  
7. Set the “MODE” switch to “CV-WIRE.”  
duty cycle of application.  
8. Set the “WELD TERMINALS” switch to “WELD  
TERMINALS REMOTELY CONTROLLED.”  
NOTE: Figure C.6 shows the electrode connected for  
positive polarity. To change polarity, shut the welder off  
and reverse the electrode and work cables at the  
Ranger 250 output terminals.  
9. Adjust wire feed speed and voltage at the LN-8.  
10. Adjust the “ARC” control to “0” initially and adjust  
to suit.  
3. Connect the K595-XX Control Cable to the LN-8.  
4. Connect the K595-XX to the 14-pin amphenol on  
the Ranger 250.  
FIGURE C.6 – RANGER 250/LN-8 WITH K595 CONTROL CABLE CONNECTION DIAGRAM  
T O LN - 8 IN P U T  
C AB LE P LU G  
K 5 9 5 C O N T R O L C AB LE  
-
1 4 P IN  
+
–
AM P H E N O L  
T O W O R K  
E LE C T R O D E C AB LE  
T O W IR E F E E D U N IT  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-9  
C-9  
ACCESSORIES  
CONNECTION OF THE LN-742 TO THE  
RANGER 250 (SEE FIGURE C.7.)  
CAUTION  
An increase of the high idle engine RPM by changing  
the governor setting or overriding the throttle linkage  
will cause an increase in the AC auxiliary voltage. If  
this voltage goes over 140 volts, wire feeder control cir-  
cuits may be damaged. The engine governor setting is  
preset at the factory – do not adjust above RPM spec-  
ifications listed in this manual.  
1. Shut the welder off.  
2. Connect the electrode cable from the LN-742 to  
the “+” terminal of the welder. Connect the work  
cable to the “-” terminal of the welder.  
NOTE: Figure C.7 shows the electrode connected for  
positive polarity. To change polarity, shut the welder off  
and reverse the electrode and work cables at the out-  
put terminals.  
7. Place the “WELD TERMINALS” switch in the  
“REMOTELY CONTROLLED” position.  
NOTE: Welding cable must be sized for current and  
duty cycle of application.  
8. Adjust wire feed speed and voltage at the LN-742.  
3. Connect the K619 Control Cable to the 14-pin  
amphenol on the Ranger 250 and the input cable  
plug on the LN-742.  
9. Set the “ARC” control to “0” initially and adjust to  
suit.  
4. Set the VOLTMETER” switch to “+” or “-” depend-  
ing on the polarity chosen.  
5. Set the “MODE” switch to the “CV-WIRE” position.  
6. Place the “IDLER” switch in the “AUTO” or “HIGH”  
position as desired.  
FIGURE C.7 – RANGER 250/LN-742 CONNECTION DIAGRAM  
-
+
–
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-10  
C-10  
NOTES  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Section D-1  
Section D-1  
TABLE OF CONTENTS  
-MAINTENANCE-  
Maintenance..........................................................................................................................Section D  
Safety Precautions......................................................................................................................D-2  
Routine and Periodic Maintenance.............................................................................................D-2  
Engine Maintenance.............................................................................................................D-2  
Engine Oil Change ........................................................................................................D-4  
Oil Filter Change ............................................................................................................D-4  
Air Cleaner Service ........................................................................................................D-4  
Spark Plug Service.........................................................................................................D-5  
Fuel Filter Service ..........................................................................................................D-5  
Engine Adjustment .........................................................................................................D-5  
Battery Maintenance.............................................................................................................D-6  
Optional Spark Arrestor........................................................................................................D-6  
Welder/Generator Maintenance..................................................................................................D-7  
Storage.................................................................................................................................D-7  
Cleaning ...............................................................................................................................D-7  
Receptacles..........................................................................................................................D-7  
Cable Connections ...............................................................................................................D-7  
Brush Removal and Replacement........................................................................................D-7  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-2  
D-2  
MAINTENANCE  
SAFETY PRECAUTIONS  
WARNING  
ROUTINE AND PERIODIC  
MAINTENANCE  
ENGINE MAINTENANCE  
• Have qualified personnel do all maintenance and  
troubleshooting work.  
CAUTION  
• Turn the engine off before working inside the  
machine.  
To prevent the engine from accidentally starting, dis-  
connect the spark plug leads before servicing the  
engine.  
• Remove guards only when necessary to perform  
maintenance and replace them when the mainte-  
nance requiring their removal is complete. If guards  
are missing from the machine, obtain replacements  
from a Lincoln Distributor. (See Operating Manual  
Parts List.)  
See Table D.1 (Kohler engine) or D.2 (Onan Engine)  
for a summary of maintenance intervals for the items  
listed in Table D.3. Follow either the hourly or the cal-  
endar intervals, whichever comes first. More frequent  
servicing may be required, depending on your specific  
application and operating conditions. See Figure D.1  
for major component locations.  
Read the Safety Precautions in the front of this manu-  
al and in the Engine Owner’s Manual before working  
on this machine.  
At the end of each day’s use, refill the fuel tank to min-  
imize moisture condensation in the tank. Running out  
of fuel tends to draw dirt into the fuel system. Also,  
check the crankcase oil level and add oil if indicated.  
Keep all equipment safety guards, covers, and devices  
in position and in good repair. Keep your hands, hair,  
clothing, and tools away from the fans, and all other  
moving parts when starting, operating, or repairing the  
equipment.  
TABLE D.1 – KOHLER ENGINE MAINTENANCE SCHEDULE  
MAINTENANCE REQUIRED  
FREQUENCY  
Daily or Before  
Starting Engine  
• Fill fuel tank  
• Check oil level  
• Check air cleaner for dirty, loose, or damaged parts  
• Check air intake and cooling areas, clean as necessary  
5 Hours  
• First Oil Change  
Every 25 Hours  
Every 100 Hours  
• Service air pre-cleaner  
• Change engine oil1  
• Replace fuel filter element  
• Clean or replace air filter element1  
• Clean spark arrestor  
Every 200 Hours  
Every 2 Years  
• Replace oil filter1  
• Check spark plug and gap  
• Check fuel lines and clamps  
1Service more frequently when used in dusty areas and/or at high ambient temperatures.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-3  
D-3  
MAINTENANCE  
TABLE D.2 – ONAN ENGINE MAINTENANCE SCHEDULE  
FREQUENCY  
MAINTENANCE REQUIRED  
Daily or Before  
Starting Engine  
• Fill fuel tank  
• Check oil level  
• Check air cleaner for dirty, loose, or damaged parts  
• Check air intake and cooling areas, clean as necessary  
5 Hours  
• First Oil Change  
Every 50 Hours  
• Service air pre-cleaner  
• Change engine oil1  
Every 100 Hours  
Every 200 Hours  
• Replace oil filter1  
• Clean spark arrestor  
• Clean or replace air filter element1  
• Replace fuel filter element  
Every 500 Hours  
Every 2 Years  
• Check spark plug and gap  
• Check fuel lines and clamps  
1Service more frequently when used in dusty areas and/or at high ambient temperatures.  
TABLE D.3 – ENGINE MAINTENANCE COMPONENTS  
ITEM  
MAKE AND PART NUMBER  
ONAN P216 ENGINE  
KOHLER CH20 ENGINE  
Kohler 1205001, Fram PH3614  
Kohler 4708303, Fram CA79  
Kohler 2408302  
Oil Filter  
Onan 122-0645, Fram PH3614  
Onan 140-2628-01, Fram CA140PL  
Onan 140-1496  
Air Filter Element  
Air Filter Pre-Cleaner  
Fuel Filter  
Onan 149-2005, Fram G1  
Kohler 2505002, Fram G1  
Champion RC12YC (.030" Gap)  
Spark Plug  
Onan 167-0263, Champion RS14YC  
(.025" Gap)  
Battery  
BCI Group 58 (435 CCA)  
BCI Group 58 (435 CCA)  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-4  
D-4  
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 socket tool to tighten the filter an additional  
1/2 to 7/8 turn.  
Drain the oil while the engine is warm to assure rapid  
and complete draining.  
1. 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.  
Push in and twist the drain valve counterclockwise.  
Pull the valve out and drain the oil into a suitable  
container.  
5. Refill the crankcase with the specified amount of  
the recommended oil. Reinstall the oil filler cap.  
6. Start the engine and check for oil filter leaks.  
7. Stop the engine and check the oil level. If neces-  
sary, add oil to the upper limit mark on the dipstick.  
2. Close the drain valve by pushing in and twisting  
clockwise. Replace the yellow cap.  
AIR CLEANER SERVICE  
3. Refill to the upper limit mark on the dipstick with the  
recommended oil. Tighten the oil filler cap securely.  
A dirty air cleaner will restrict air flow to the carburetor.  
To prevent carburetor malfunction, service the air  
cleaner regularly. Service more frequently when oper-  
ating the engine in extremely dusty areas.  
Engine Oil Refill Capacities  
Without oil filter replacement:  
• 1.7 US qt. (1.4 Imp qt., 1.6 liter) - Kohler  
• 1.6 US qt. (1.3 Imp qt., 1.5 liter) - Onan  
WARNING  
Never use gasoline or low flash point solvents for  
cleaning the air cleaner element. A fire or explosion  
could result.  
With oil filter replacement:  
• 2.0 US qt. (1.7 Imp qt., 1.9 liter) - Kohler  
• 1.8 US qt. (1.5 Imp qt., 1.7 liter) - Onan  
Use 4-cycle motor oil that meets or exceeds the  
requirements for API service classification SG or SH.  
Always check the API SERVICE label on the oil con-  
tainer to be sure it includes the letters SG or SH.  
CAUTION  
Never run the engine without the air cleaner. Rapid  
engine wear will result from contaminants, such as  
dust and dirt being drawn into the engine.  
SAE 10W-30 is recommended for general, all-temper-  
ature use, -5°F to 104°F (-20°C to 40°C). For the Onan  
engine, it is recommended that SAE 30 oil be used  
above 82°F (27°C). See the engine Owner’s Manual  
for more specific information on oil viscosity recom-  
mendations.  
Air Pre-Cleaner Service  
Wash your hands with soap and water after handling  
used oil.  
1. Loosen the cover retaining knob and remove the  
cover.  
Please dispose of used motor oil in a manner that is  
compatible with the environment. We suggest you  
take it in a sealed container to your local service sta-  
tion or recycling center for reclamation. Do not throw it  
in the trash, pour it on the ground or down a drain.  
2. Remove the pre-cleaner from the paper element.  
3. Wash the pre-cleaner in warm water with deter-  
gent. Rinse the pre-cleaner thoroughly until all  
traces of detergent are eliminated. Squeeze out  
excess water (do not wring). Allow the pre-cleaner  
to air dry.  
OIL FILTER CHANGE  
4. Saturate the pre-cleaner with new engine oil.  
Squeeze out all excess oil.  
1. Drain the engine oil.  
2. Remove the oil filter, and drain the oil into a suit-  
able container. Discard the used oil filter.  
5. Reinstall the pre-cleaner over the paper element.  
6. Reinstall the air cleaner cover. Secure the cover  
with the cover retaining knob.  
3. Clean the filter mounting base and coat the gasket  
of the new oil filter with clean engine oil.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-5  
D-5  
MAINTENANCE  
Air Filter Paper Element Service  
7. After the spark plug is seated, tighten with a spark  
plug wrench to compress the washer.  
1. Loosen the cover retaining knob and remove the  
cover.  
• If installing a new spark plug, tighten 1/2 turn after  
the spark plug seats to compress the washer.  
2. Remove the pre-cleaner from the paper element.  
• If reinstalling a used spark plug, tighten 1/8 - 1/4  
turn after the spark plug seats to compress the  
washer.  
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. Replace a  
dirty, bent, or damaged element with a new ele-  
ment. Handle new elements carefully; do not use  
if the sealing surfaces are bent or damaged.  
Spark Plug Gap: .030 in. (0.76 mm)-Kohler  
.025 in. (0.64 mm)-Onan  
Spark Plug Torque: 20 ft. Lb. (27 N-m)-Kohler  
11 ft. Lb. (14 N-m)-Onan  
5. When servicing the air cleaner, check the air  
cleaner base. Make sure it is secured and not bent  
or damaged. Also check the element cover for  
damaged or improper fit. Replace all damaged air  
cleaner components.  
CAUTION  
The spark plug must be securely tightened. An improp-  
erly tightened spark plug can become very hot and  
may cause engine damage.  
NOTE: Before the air cleaner is reassembled, make  
sure rubber seal is in position around the stud. Inspect,  
making sure it is not damaged and seals with the ele-  
ment cover.  
Use only the recommended spark plug or equivalent.  
A spark plug which has an improper heat range may  
cause engine damage.  
6. Reinstall the paper element, pre-cleaner, element  
cover, element cover nut, and air cleaner cover.  
Secure the cover with the cover retaining knob.  
FUEL FILTER SERVICE  
1. Check the fuel filter for water accumulation or sed-  
iment.  
SPARK PLUG SERVICE  
To ensure proper engine operation, the spark plugs  
must be properly gapped and free of deposits.  
2. Replace the fuel filter if it is found with excessive  
water accumulation or sediment.  
ENGINE ADJUSTMENT  
WARNING  
The muffler becomes very hot during operation and  
remains hot for a while after stopping the engine. Be  
careful not to touch the muffler while it is hot.  
WARNING  
OVERSPEED IS HAZARDOUS.  
The maximum allowable high idle speed for this  
machine is 3750 RPM, no load. Do NOT tamper with  
governor components or setting or make any other  
adjustments to increase the maximum speed. Severe  
personal injury and damage to the machine can result  
if operated at speeds above maximum.  
1. Remove the spark plug cap.  
2. Clean any dirt from around the spark plug base.  
3. Use a plug wrench to remove the spark plugs.  
4. Visually inspect the spark plugs. Discard them if  
the insulator is cracked or chipped. Clean the  
spark plug with a wire brush if it is to be reused.  
Adjustments to the engine are to be made only by a  
Lincoln Service Center or an authorized Field Service  
Shop.  
5. Measure the plug gap with a feeler gauge. Correct  
as necessary by bending the side electrode.  
6. Check that the spark plug washer is in good condi-  
tion and thread the spark plug in by hand to pre-  
vent cross-threading.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-6  
D-6  
MAINTENANCE  
After cleaning, flush the outside of the battery, the bat-  
tery compartment, and surrounding areas with clear  
water. Coat the battery terminals lightly with petroleum  
jelly or a non-conductive grease to retard corrosion.  
BATTERY MAINTENANCE  
To access the battery, remove the screws from the rear  
battery tray using a screwdriver or a 3/8" socket. Slide  
the battery tray out only far enough to access the bat-  
tery terminals.  
Keep the battery clean and dry. Moisture accumulation  
on the battery can lead to more rapid discharge and  
early battery failure.  
WARNING  
CHECKING ELECTROLYTE LEVEL  
GASES FROM BATTERY can explode.  
If battery cells are low, fill them to the neck of the filler  
hole with distilled water and recharge. If one cell is low,  
check for leaks.  
• Keep sparks, flame, and cigarettes  
away from battery.  
CHARGING THE BATTERY  
To prevent EXPLOSION when:  
When you charge, jump, replace, or otherwise connect  
battery cables to the battery, be sure the polarity is cor-  
rect. Improper polarity can damage the charging cir-  
cuit. The Ranger 250 positive (+) battery terminal has  
a red terminal cover.  
• INSTALLING A NEW BATTERY - Disconnect the  
negative cable from the old battery first and connect  
to the new battery last.  
• CONNECTING A BATTERY CHARGER - Remove  
the battery from the welder by disconnecting the  
negative cable first, then the positive cable and bat-  
tery clamp. When reinstalling, connect the negative  
cable last. Keep the area well ventilated.  
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.  
After the battery is charged, reconnect the positive bat-  
tery cable first and the negative cable last. Failure to  
do so can result in damage to the internal charger com-  
ponents.  
• USING A BOOSTER - Connect the positive lead to  
the battery first, then connect the negative lead to the  
engine foot.  
Follow the instructions of the battery charger manufac-  
turer for proper charger settings and charging time.  
BATTERY ACID can burn eyes and  
skin.  
OPTIONAL SPARK ARRESTOR  
• Wear gloves and eye protection and be  
careful when working near a battery.  
WARNING  
• Follow the instructions printed on the  
battery.  
MUFFLER MAY BE HOT.  
Allow the engine to cool before installing the spark  
arrestor!  
CLEANING THE BATTERY  
Do not operate the engine while installing the spark  
arrestor!  
Keep the battery clean by wiping it with a damp cloth  
when dirty. If the terminals appear corroded, discon-  
nect the battery cables and wash the terminals with an  
ammonia solution or a solution of 1/4 pound (0.113 kg)  
of baking soda and 1 quart (0.946 l) of water. Be sure  
the battery vent plugs (if equipped) are tight so that  
none of the solution enters the cells.  
Clean the spark arrestor after every 100 hours of use.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-7  
D-7  
MAINTENANCE  
WELDER/GENERATOR  
MAINTENANCE  
CAUTION  
Do not attempt to polish slip rings while the engine is  
running.  
STORAGE  
Store the Ranger 250 in clean, dry, protected areas.  
WARNING  
CLEANING  
Service and repair should only be performed by Lincoln  
Electric Factory Trained Personnel. Unauthorized  
repairs performed on this equipment may result in dan-  
ger 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.  
Blow out the generator and controls periodically with  
low pressure air. Do this at least once a week in par-  
ticularly dirty areas.  
RECEPTACLES  
Keep the electrical receptacles in good condition.  
Remove any dirt, oil, or other debris from their surfaces  
and holes.  
CABLE CONNECTIONS  
Check the welding cable connections at the weld out-  
put terminals often. Be sure that the connections are  
always firm.  
BRUSH REMOVAL AND REPLACEMENT  
It’s normal for the brushes and slip rings to wear and  
darken slightly. Inspect the brushes when a generator  
overhaul is necessary.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-8  
D-8  
MAINTENANCE  
FIGURE D.1 – MAJOR COMPONENT LOCATIONS  
1
1. CASE COVER AND DOOR ASSEMBLY/CASE BACK  
2. ENGINE  
3. IDLER SOLENOID  
4. ROTOR/STATOR  
5. POWER MODULE ASSEMBLY  
6. POWER CAPACITORS  
7. PC BOARDS  
8. FRONT PANEL (OUTPUT) ASSEMBLY  
9. CONTROL PANEL  
10. OUTPUT CHOKE  
11. OUTPUT RECTIFIER BRIDGE  
12. FUEL TANK  
13. MACHINE BASE  
14. BATTERY  
2
5
3
6
4
14  
7
8
9
13  
12  
11  
10  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Section E-1  
Section E-1  
TABLE OF CONTENTS  
-THEORY OF OPERATION SECTION-  
Theory of Operation .............................................................................................................Section E  
General Description ..............................................................................................................E-2  
Battery, Engine, Rotor, Stator and Engine Protection ...........................................................E-2  
Weld Windings, Rectifier, Power Module and Feedback.......................................................E-3  
Analog Power Board and Control Board ...............................................................................E-4  
Insulated Gate Bipolar Transistor (IGBT) Operation .............................................................E-5  
Pulse Width Modulation.........................................................................................................E-6  
Chopper Technology Fundamentals......................................................................................E-7  
FIGURE E.1 – RANGER 250 BLOCK LOGIC DIAGRAM  
WORK  
TERMINAL  
THREE-PHASE  
RECTIFIER  
__  
TO  
CONTROL  
BOARD  
ELECTRODE  
TERMINAL  
+
IGBT  
CHOKE  
+
SHUNT  
4
0
POWER MODULE  
F
D
W
E
E
D
B
A
C
K
TO  
L
I
2
0
S
I
G
N
A
L
1
0
0
E
N
FROM  
P
TOROID  
CURRENT  
SENSOR  
W
D
W
M
V
D
C
I
N
V
D
C
G
S
ANALOG  
POWER  
BOARD  
GAS  
CONTROL  
BOARD  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
STARTER  
SLIP  
RINGS  
FLYWHEEL  
ALTERNATOR  
REGULATED VOLTAGES  
ARC  
OUTPUT  
MODE  
CONTROL CONTROL SELECTOR  
STATOR  
OIL  
PRESSURE  
SWITCH  
FIELD  
WINDING  
AUXILIARY  
WINDINGS  
WIRE FEED  
PWR WNDG  
SOL  
4
2
I
4
2
D
L
E
R
BATTERY  
V
A
C
V
A
C
RUN/STOP  
SWITCH  
2
4
0
1
2
0
AMPHENOL  
V
A
C
V
A
C
TO CONTROL  
BOARD  
BATTERY  
BOARD  
240VAC  
120VAC  
RECEPTACLE  
RECEPTACLE  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-2  
E-2  
THEORY OF OPERATION  
FIGURE E.2 – BATTERY, STARTER, ENGINE, ROTOR, STATOR AND ENGINE PROTECTION  
WORK  
TERMINAL  
THREE-PHASE  
RECTIFIER  
__  
TO  
CONTROL  
BOARD  
ELECTRODE  
TERMINAL  
+
IGBT  
CHOKE  
+
SHUNT  
4
0
POWER MODULE  
F
D
W
E
E
D
B
A
C
K
TO  
L
I
2
0
S
I
G
N
A
L
1
0
0
E
N
FROM  
TOROID  
P
W
D
W
M
CURRENT  
SENSOR  
V
D
C
I
N
V
D
C
G
S
ANALOG  
POWER  
BOARD  
GAS  
CONTROL  
BOARD  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
STARTER  
SLIP  
RINGS  
FLYWHEEL  
ALTERNATOR  
REGULATED VOLTAGES  
ARC  
OUTPUT  
MODE  
CONTROL CONTROL SELECTOR  
STATOR  
OIL  
PRESSURE  
SWITCH  
FIELD  
WINDING  
AUXILIARY  
WINDINGS  
WIRE FEED  
PWR WNDG  
SOL  
4
2
I
4
2
D
L
E
R
BATTERY  
V
A
C
V
A
C
RUN/STOP  
SWITCH  
2
4
0
1
2
0
AMPHENOL  
V
A
C
V
A
C
TO CONTROL  
BOARD  
BATTERY  
BOARD  
240VAC  
120VAC  
RECEPTACLE  
RECEPTACLE  
GENERAL DESCRIPTION  
The Ranger 250 is a gasoline engine-driven welding  
power source capable of producing 250 amps at  
25VDC at a 100% duty cycle. The engine is coupled to  
a brush-type alternating current generator. This AC  
output is rectified and controlled by Chopper  
Technology to produce DC current for multi-purpose  
welding applications. The Ranger 250 is also capable  
of producing 8,000 watts of AC auxiliary power at 100%  
duty cycle.  
netizes the rotor lamination. This rotating magnet  
induces a voltage in the stationary windings of the main  
alternator stator. The stator houses a three-phase weld  
winding, a 120/240VAC single-phase auxiliary winding,  
a 42VAC wire feeder power winding, and a separate  
42VAC field feedback winding that is rectified and  
serves as a feedback supply for the rotor field winding.  
The engine flywheel alternator supplies charging cur-  
rent for the battery circuit. The oil pressure switch mon-  
itors engine oil pressure. If a low oil pressure condition  
should develop, the engine will shut down and the bat-  
tery PC board will disable the rotor flashing current.  
The idler solenoid is mechanically connected to the  
engine’s throttle linkage. If no welding or auxiliary cur-  
rent is being drawn from the Ranger 250, the control  
board activates the idler solenoid, which then brings  
the engine to a low idle state. When either welding or  
auxiliary current is detected at the toroid current sen-  
sor, the control board deactivates the idler solenoid and  
the engine returns to high RPM.  
BATTERY, ENGINE, ROTOR, STA-  
TOR AND ENGINE PROTECTION  
The 12VDC battery powers the engine starter motor  
and also supplies power to the battery PC board and  
associated circuitry. When the engine, which is  
mechanically coupled to the rotor, is started and run-  
ning, the 12 VDC battery voltage is fed through the bat-  
tery board to the rotor field coil via a brush and slip ring  
configuration. This excitation or “flashing” voltage mag-  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-3  
E-3  
THEORY OF OPERATION  
FIGURE E.3 – WELD WINDINGS, RECTIFIER, POWER MODULE AND FEEDBACK  
WORK  
TERMINAL  
THREE-PHASE  
RECTIFIER  
__  
TO  
CONTROL  
BOARD  
ELECTRODE  
TERMINAL  
+
IGBT  
CHOKE  
+
SHUNT  
4
0
POWER MODULE  
F
D
W
E
E
D
B
A
C
K
TO  
L
I
2
0
S
I
G
N
A
L
1
0
0
E
N
FROM  
P
TOROID  
CURRENT  
SENSOR  
W
D
W
M
V
D
C
I
N
V
D
C
G
S
ANALOG  
POWER  
BOARD  
GAS  
CONTROL  
BOARD  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
STARTER  
SLIP  
RINGS  
FLYWHEEL  
ALTERNATOR  
REGULATED VOLTAGES  
ARC  
OUTPUT  
MODE  
CONTROL CONTROL SELECTOR  
STATOR  
OIL  
PRESSURE  
SWITCH  
FIELD  
WINDING  
AUXILIARY  
WINDINGS  
WIRE FEED  
PWR WNDG  
SOL  
4
2
I
4
2
D
L
E
R
BATTERY  
V
A
C
V
A
C
RUN/STOP  
SWITCH  
2
4
0
1
2
0
AMPHENOL  
V
A
C
V
A
C
TO CONTROL  
BOARD  
BATTERY  
BOARD  
240VAC  
120VAC  
RECEPTACLE  
RECEPTACLE  
WELD WINDINGS, RECTIFIER,  
POWER MODULE AND FEEDBACK  
The three-phase stator weld windings are connected to  
a three-phase rectifier bridge. The resultant DC volt-  
age is applied to parallel capacitors incorporated with-  
in the power module. These capacitors function as fil-  
ters and also as power supplies for the IGBT. See  
IGBT Operation in this section. The IGBT acts as a  
high-speed switch operating at 20KHZ. This device is  
switched on and off by the control board through  
pulsewidth modulation circuitry. See Pulse Width  
Modulation in this section. This “chopped” DC output  
is applied through a choke coil and shunt to the weld-  
ing output terminals. The choke functions as a current  
filter. Free-wheeling diodes are incorporated in the  
power module to provide a current path for the stored  
energy in the chokes when the IGBT is turned off. See  
Chopper Technology in this section.  
Output voltage and current feedback information is fed  
to the control board. This information is sensed from  
the output terminal circuits and the shunt.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-4  
E-4  
THEORY OF OPERATION  
FIGURE E.4 – ANALOG POWER BOARD AND CONTROL BOARD  
WORK  
TERMINAL  
THREE-PHASE  
RECTIFIER  
__  
TO  
CONTROL  
BOARD  
ELECTRODE  
TERMINAL  
+
IGBT  
CHOKE  
+
SHUNT  
4
0
POWER MODULE  
F
D
W
E
E
D
B
A
C
K
TO  
L
I
2
0
S
I
G
N
A
L
1
0
0
E
N
FROM  
TOROID  
P
W
D
W
M
CURRENT  
SENSOR  
V
D
C
I
N
V
D
C
G
S
ANALOG  
POWER  
BOARD  
GAS  
CONTROL  
BOARD  
MECHANICAL  
ROTATION  
ENGINE  
ROTOR  
STARTER  
SLIP  
RINGS  
FLYWHEEL  
ALTERNATOR  
REGULATED VOLTAGES  
ARC  
OUTPUT  
MODE  
CONTROL CONTROL SELECTOR  
STATOR  
OIL  
PRESSURE  
SWITCH  
FIELD  
WINDING  
AUXILIARY  
WINDINGS  
WIRE FEED  
PWR WNDG  
SOL  
4
2
I
4
2
D
L
E
R
BATTERY  
V
A
C
V
A
C
RUN/STOP  
SWITCH  
2
4
0
1
2
0
AMPHENOL  
V
A
C
V
A
C
TO CONTROL  
BOARD  
BATTERY  
BOARD  
240VAC  
120VAC  
RECEPTACLE  
RECEPTACLE  
ANALOG POWER BOARD AND  
CONTROL BOARD  
The analog power board, which is powered by the two  
filter capacitors on the power module, supplies various  
regulated DC voltages to operate the control board cir-  
cuitry. It also supplies a regulated DC voltage to oper-  
ate the chopper board.  
control, output, and mode selector). It compares these  
commands to the current and voltage feedback infor-  
mation it receives from the shunt and output terminal  
circuits. The circuitry on the control board determines  
how the output should be controlled to optimize weld-  
ing results, and it sends the correct PWM signals to the  
IGBT driver circuit.  
The control board monitors the operator controls (arc  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-5  
E-5  
THEORY OF OPERATION  
FIGURE E.5 – IGBT OPERATION  
POSITIVE  
VOLTAGE  
APPLIED  
GATE  
GATE  
SOURCE  
SOURCE  
n +  
n +  
n +  
n +  
p
BODY REGION  
p
BODY REGION  
DRAIN DRIFT REGION  
DRAIN DRIFT REGION  
n -  
n -  
n +  
p +  
BUFFER LAYER  
n +  
p +  
BUFFER LAYER  
INJECTING LAYER  
INJECTING LAYER  
DRAIN  
DRAIN  
B. ACTIVE  
A. PASSIVE  
INSULATED GATE BIPOLAR  
TRANSISTOR (IGBT) OPERATION  
An IGBT is a type of transistor. IGBTs are semiconduc-  
tors well suited for high frequency switching and high  
current applications.  
Drawing B shows the IGBT in an active mode. When  
the gate signal, a positive DC voltage relative to the  
source, is applied to the gate terminal of the IGBT, it is  
capable of conducting current. A voltage supply con-  
nected to the drain terminal will allow the IGBT to con-  
duct and supply current to circuit components coupled  
to the source. Current will flow through the conducting  
IGBT to downstream components as long as the posi-  
tive gate signal is present. This is similar to turning ON  
a light switch.  
Drawing A shows an IGBT in a passive mode. There is  
no gate signal, zero volts relative to the source, and  
therefore, no current flow. The drain terminal of the  
IGBT may be connected to a voltage supply; but since  
there is no conduction the circuit will not supply current  
to components connected to the source. The circuit is  
turned off like a light switch in the OFF position.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-6  
E-6  
THEORY OF OPERATION  
FIGURE E.6 – TYPICAL IGBT OUTPUTS  
MINIMUM OUTPUT  
(Dwell or Off Time)  
sec  
sec  
sec  
48  
50  
2
MAXIMUM OUTPUT  
(Dwell or Off Time)  
sec  
sec  
48  
50  
PULSE WIDTH MODULATION  
The term PULSE WIDTH MODULATION is used to  
describe how much time is devoted to conduction in the  
cycle. Changing the pulse width is known as MODU-  
LATION. Pulse Width Modulation (PWM) is the varying  
of the pulse width over the allowed range of a cycle to  
affect the output of the machine.  
The positive portion of the signal represents one IGBT  
group conducting for 2 microsecond. The dwell time (off  
time) is 48 microseconds. Since only 2 microseconds of  
the 50-microsecond time period is devoted to conduct-  
ing, the output power is minimized.  
MAXIMUM OUTPUT  
MINIMUM OUTPUT  
By holding the gate signals on for 48 microseconds and  
allowing only 2 microseconds of dwell time (off time)  
during the 50-microsecond cycle, the output is maxi-  
mized. The darkened area under the top curve can be  
compared to the area under the bottom curve. The  
more darkened area under the curve, the more power  
is present.  
By controlling the duration of the gate signal, the IGBT  
is turned on and off for different durations during a  
cycle. The top drawing shows the minimum output sig-  
nal possible over a 50-microsecond time period.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-7  
E-7  
THEORY OF OPERATION  
CHOPPER TECHNOLOGY  
FUNDAMENTALS  
The new era of welding machines such as the Ranger  
250 employ a technology whereby a DC source is  
turned on and off (chopped up) at high speed,  
thensmoothed through an inductor to control an arc.  
Hence the name “Chopper.” The biggest advantage of  
chopper technology is the high-speed control of the  
arc, similar to the inverter machines. A block diagram  
for this is as follows:  
3 PHASE  
ALTERNATOR  
DC RECTIFIER  
AND FILTER  
SOLID STATE  
INDUCTOR  
AND DIODE  
ARC  
SWITCH  
ARC  
CONTROL  
In this system, the engine drives a three-phase alter-  
nator, which generates power that is rectified and fil-  
tered to produce about 85VDC. The current is applied  
through a solid state switch to an inductor. By turning  
the switch on and off, current in the inductor and the  
arc can be controlled. The following diagram depicts  
the current flow in the system when the switch is open  
and closed:  
INDUCTOR  
SWITCH  
DIODE  
ARC  
85VDC  
CURRENT WITH SWITCH OPEN  
CURRENT WITH SWITCH CLOSED  
When the switch is closed, current is applied through  
the inductor to the arc. When the switch opens, current  
stored in the inductor sustains flow in the arc and  
through the diode. The repetition rate of switch closure  
is 20Khz, which allows ultra-fast control of the arc. By  
varying the ratio of on time versus off time of the switch  
(Duty Cycle), the current applied to the arc is con-  
trolled. This is the basis for Chopper Technology:  
Controlling the switch in such a way as to produce  
superior welding.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-8  
E-8  
NOTES  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Section F-1  
Section F-1  
TABLE OF CONTENTS  
TROUBLESHOOTING & REPAIR SECTION  
Troubleshooting & Repair Section ................................................................................Section F  
How to Use Troubleshooting Guide.......................................................................................F-2  
PC Board Troubleshooting Procedures .................................................................................F-3  
Troubleshooting Guide................................................................................................F-4 - F-12  
Test Procedures...................................................................................................................F-13  
Case Cover Removal and Replacement Procedure ....................................................F-13  
Power Module Capacitor Discharge Procedure ...........................................................F-15  
Idler Solenoid Test ........................................................................................................F-17  
Engine Throttle Adjustment Test ...................................................................................F-19  
Rotor Resistance Test ..................................................................................................F-23  
Flashing and Rotor Voltage Test ..................................................................................F-25  
Stator Voltage Tests .....................................................................................................F-28  
Analog Power PC Board Voltage Test .........................................................................F-33  
Output Rectifier Bridge Test .........................................................................................F-36  
Power Module Test .......................................................................................................F-39  
Flywheel Alternator Test ................................................................................................F-43  
Oscilloscope Waveforms......................................................................................................F-45  
Normal Open Circuit Voltage Waveform (120 VAC Supply)..........................................F-45  
Normal Open Circuit Voltage Waveform (Stick)............................................................F-46  
Normal Weld Voltage Waveform (Stick CC)..................................................................F-47  
Normal Open Circuit Voltage Waveform (Wire CV Tap)................................................F-48  
Normal Weld Voltage Waveform (Wire CV) ..................................................................F-49  
Replacement Procedures ....................................................................................................F-50  
Power Module Assembly/Power Module PC Board/  
Diode Module Removal and Replacement....................................................................F-50  
Power Capacitor Removal and Replacement ...............................................................F-55  
Output Rectifier Bridge and Choke Removal and Replacement...................................F-57  
Engine/Stator/Rotor Removal and Replacement ..........................................................F-60  
Retest After Repair...............................................................................................................F-68  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-2  
F-2  
TROUBLESHOOTING & REPAIR  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and repair should be performed by only 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.  
This Troubleshooting Guide is provided to help  
you locate and repair possible machine malfunc-  
tions. Simply follow the three-step procedure list-  
ed below.  
Step 3. PERFORM COMPONENT TESTS. The  
last column, labeled “Recommended Course of  
Action” lists the most likely components that may  
have failed in your machine. It also specifies the  
appropriate test procedure to verify that the sub-  
ject component is either good or bad. If there are  
a number of possible components, check the  
components in the order listed to eliminate one  
possibility at a time until you locate the cause of  
your problem.  
Step 1. LOCATE PROBLEM (SYMPTOM). Look  
under the column labeled “PROBLEM” (SYMP-  
TOMS). This column describes possible symp-  
toms that the machine may exhibit. Find the list-  
ing that best describes the symptom that the  
machine is exhibiting. Symptoms are grouped  
into four main categories: Output Problems,  
Function Problems, Engine Problems, and  
Welding Problems.  
All of the referenced test procedures referred to in  
the Troubleshooting Guide are described in detail  
at the end of this section.  
Refer to the  
Troubleshooting and Repair Table of Contents to  
locate each specific Test Procedure. All of the  
referred to test points, components, terminal  
strips, etc., can be found on the referenced elec-  
trical wiring diagrams and schematics. Refer to  
the Electrical Diagrams Section Table of Contents  
to locate the appropriate diagram.  
Step 2. PERFORM EXTERNAL TESTS. The  
second column, labeled “POSSIBLE AREAS OF  
MISADJUSTMENT(S)”, lists the obvious external  
possibilities that may contribute to the machine  
symptom. Perform these tests/checks in the  
order listed. In general, these tests can be con-  
ducted without removing the case cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs  
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before  
you proceed. Call 1-800-833-9353.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-3  
F-3  
TROUBLESHOOTING & REPAIR  
PC BOARD TROUBLESHOOTING PROCEDURES  
• Remove the PC Board from the static-shielding bag  
and place it directly into the equipment. Don’t set the  
PC Board on or near paper, plastic or cloth which  
could have a static charge. If the PC Board can’t be  
installed immediately, put it back in the static-shielding  
bag.  
WARNING  
ELECTRIC SHOCK can kill.  
Have an electrician install and service  
this equipment. Turn the machine OFF  
before working on equipment. Do not  
touch electrically hot parts.  
• If the PC Board uses protective shorting jumpers,  
don’t remove them until installation is complete.  
• If you return a PC Board to The Lincoln Electric  
Company for credit, it must be in the static-shielding  
bag. This will prevent further damage and allow prop-  
er failure analysis.  
Sometimes machine failures appear to be due to PC  
board failures. These problems can sometimes be  
traced to poor electrical connections. To avoid prob-  
lems when troubleshooting and replacing PC boards,  
please use the following procedure:  
4. Test the machine to determine if the failure symp-  
tom has been corrected by the replacement PC  
board.  
1. Determine to the best of your technical ability that  
the PC board is the most likely component causing  
the failure symptom.  
NOTE: Allow the machine to heat up so that all elec-  
trical components can reach their operating tempera-  
ture.  
2. Check for loose connections at the PC board to  
assure that the PC board is properly connected.  
5. Remove the replacement PC board and substitute  
it with the original PC board to recreate the original  
problem.  
3. If the problem persists, replace the suspect PC  
board using standard practices to avoid static elec-  
trical damage and electrical shock. Read the warn-  
ing inside the static resistant bag and perform the  
following procedures:  
a. If the original problem does not reappear  
by substituting the original board, then the  
PC board was not the problem. Continue  
to look for bad connections in the control  
wiring harness, junction blocks, and termi-  
nal strips.  
PC Board can be damaged by static electricity.  
• Remove your body’s static charge  
before opening the static-shield-  
ing bag. Wear an anti-static wrist  
strap. For safety, use a 1 Meg  
ohm resistive cord connected to a  
grounded part of the equipment  
b. If the original problem is recreated by the  
substitution of the original board, then the  
PC board was the problem. Reinstall the  
replacement PC board and test the  
machine.  
frame.  
6. Always indicate that this procedure was followed  
when warranty reports are to be submitted.  
ATTENTION  
Static-Sensitive  
Devices  
Handle only at  
Static-Safe  
Workstations  
• If you don’t have a wrist strap,  
touch an unpainted, grounded,  
part of the equipment frame.  
Keep touching the frame to pre-  
vent static build-up. Be sure not  
to touch any electrically live parts  
NOTE: Following this procedure and writing on the  
warranty report, “INSTALLED AND SWITCHED PC  
BOARDS TO VERIFY PROBLEM,” will help avoid  
denial of legitimate PC board warranty claims.  
Reusable  
Container  
at the same time.  
• Tools which come in contact with  
the PC Board must be either con-  
ductive, anti-static or static-dissi-  
pative.  
Do Not Destroy  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-4  
F-4  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major physical or electrical damage 1. Contact your local Lincoln 1. Contact the Lincoln Electric  
is evident.  
Authorized  
Facility.  
Field  
Service  
Service Department at 1-800-  
833-9353 (WELD).  
No welding output in all modes. 1. Place the Welding Terminals  
1. Check for loose or faulty con-  
nections on the heavy current  
carrying leads between the  
output bridge, the power mod-  
ule, the choke, the shunt and  
the output terminals. Check  
thermostat TS1 and associated  
The engine operates normally. The  
auxiliary output is normal.  
switch in the “WELD TERMI-  
NALS ON” position. If the prob-  
lem is solved, the fault may be  
in the external control cable (if  
used), leads #2 and #4. See  
the Wiring Diagram.  
wiring.  
Diagram.  
See the Wiring  
2. With the engine at high idle  
(3700RPM), the machine in the  
Stick mode and the OUTPUT  
CONTROL at maximum, check  
for the presence of approxi-  
mately 80VDC (open circuit  
voltage) at the output terminals.  
2. Check the Welding Terminals  
switch and associated leads (2  
and 4).  
Diagram.  
See the Wiring  
3. If the correct OCV is present  
when the Welding Terminals  
switch is in the “WELD TERMI-  
NALS ON” position, the By-  
pass Board may be faulty. Also  
check associated wiring. See  
the Wiring Diagram.  
3. If the correct OCV is present at  
the welding output terminals,  
check the welding cables,  
clamps and electrode holder for  
loose or faulty connections.  
4. Air flow may be blocked or  
restricted.  
4. Check gate leads (#23 and  
#25) for loose or faulty connec-  
tions. See the Wiring Diagram.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-5  
F-5  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No welding output in all modes.  
The engine operates normally. The  
auxiliary output is normal.  
5. Perform the Stator Voltage  
Test.  
6. Perform the Output Rectifier  
(continued)  
Bridge Test.  
7. Perform the Power Module  
Test.  
8. Perform the Analog Power  
Board Test.  
9. Check the output control  
potentiometer and associated  
wiring.  
10. The Control Board may be  
faulty.  
No welding output in all modes. 1. Check the brushes for wear and 1. Perform the Rotor Resistance  
Also no auxiliary power. The  
engine operates normally at  
approximately 3700 RPM.  
proper contact to the rotor slip  
rings.  
Test.  
2. Perform the Flashing and  
Rotor Voltage Test. If the  
“flashing” voltage is not present,  
the battery board or leads #201  
or #200 may be faulty. See the  
Wiring Diagram. Also, make  
sure that lead #5H has continu-  
ity (zero ohms) to ground.  
2. Make sure the engine is operat-  
ing at the correct high idle  
speed (3700 RPM).  
3. Check for loose or faulty con-  
nections or leads at the auxiliary  
output receptacles and/or the  
welder output terminals. See  
the Wiring Diagram.  
3. Check the field diode and  
capacitor. Replace if neces-  
sary.  
4. Perform the Stator Voltage  
Test.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-6  
F-6  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No auxiliary power at the recepta- 1. The circuit breakers may be 1. Check the wiring between the  
cles. The welding output is normal  
and the engine operates normally.  
tripped. Reset if necessary.  
auxiliary receptacles, the con-  
nection studs, and the main sta-  
tor. See the Wiring Diagram.  
2. Check for loose or faulty con-  
nections at the auxiliary recep-  
tacles.  
2. Perform the Stator Voltage  
Test.  
The machine has welding output 1. If a remote control unit is con- 1. Check the OUTPUT control  
but no control of output in some or  
all modes. The auxiliary power is  
normal.  
nected, check the remote control  
and related cable.  
potentiometer and related  
leads. See the Wiring Diagram.  
2. Check the welding and work 2. Check the shunt and associated  
cables for loose or faulty con-  
nections.  
feedback leads. See the Wiring  
Diagram.  
3. Check the voltage feedback  
leads for loose or faulty connec-  
tions. See the Wiring Diagram.  
4. Perform the Power Module  
Test.  
5. The Control Board may be  
faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-7  
F-7  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
The machine has low welding out- 1. The engine RPM may be low.  
1. If the engine high idle speed is  
low, perform the Engine  
Throttle Adjustment Test.  
put and low auxiliary output.  
2. Check the brushes for wear and  
proper contact to the slip rings.  
2. Perform the Rotor Resistance  
Test.  
3. Perform the Flashing and  
Rotor Voltage Test. If the rotor  
voltage is low, the field capaci-  
tor or field bridge may be faulty.  
Test and replace if necessary.  
See the Wiring Diagram.  
4. If the engine high idle RPM is  
OK but slows down excessively  
under load, then the engine  
may have lost horsepower and  
be in need of major repair.  
The machine control is still active 1. This is normal in TIG mode.  
1. Check Plug J10 on the Control  
Board for loose or faulty con-  
nections.  
when the remote control unit is  
2. The remote control unit may be  
connected.  
defective.  
2. The bypass board may be  
faulty.  
3. Check the amphenol connec-  
tions and associated wiring.  
3. The Control Board may be  
faulty.  
Machine seems to be locked into 1. Check the position of the Mode 1. Check the Mode Selector switch  
the CC mode of operation (stick  
mode.)  
Selector switch. It must be in  
the correct position for the  
process being used.  
and associated wiring. See the  
Wiring Diagram.  
2. The Control Board may be  
faulty.  
2. Check that jumper plug J3 is  
properly installed in the Control  
Board. (J3 has a jumper wire  
from pin 1 to pin 5.)  
3. Make sure plug J2 is properly  
connected to the Control Board.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-8  
F-8  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
FUNCTION PROBLEMS  
The wire feeder does not work 1. Check the appropriate circuit 1. Check for the presence of  
when connected to the welder  
amphenol.  
breaker (CB1 or CB8). Reset if  
tripped.  
appropriate source voltage at  
the 14-pin amphenol.  
2. The wire feeder control cable 2. If the appropriate voltage (42  
may be faulty.  
VAC or 115 VAC) is NOT pre-  
sent at the 14-pin amphenol,  
check for loose or faulty con-  
3. The wire feeder may be faulty.  
nections.  
Diagram.  
See the Wiring  
3. Perform the Stator Voltage  
Test.  
The battery does not stay charged. 1. Check for loose or faulty con- 1. If the yellow engine alternator  
nections at the battery and  
engine charging system.  
light is on, perform the  
Flywheel Alternator Test.  
2. The battery may be faulty. 2. If the battery is not charging and  
Check or replace.  
the yellow engine alternator  
light is not lit. The battery board  
may be faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-9  
F-9  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine will not crank when the 1. Check the circuit breaker (CB7). 1. If the battery is replaced or tests  
start button is pushed.  
Reset if tripped.  
good, then the charging circuit  
may be faulty. Perform the  
Flywheel Alternator Test.  
2. Make sure the Run/Stop switch  
is in the “RUN” position.  
2. The starter motor or starter  
solenoid may be faulty.  
3. Check for loose or faulty battery  
cable connections.  
3. The engine may be hard to  
crank due to a mechanical fail-  
ure in the engine.  
4. The battery may be low or faulty.  
5. The Start button may be faulty.  
The engine cranks but will not start. 1. Check for adequate fuel supply. 1. The oil pressure switch may be  
faulty. See the Wiring Diagram.  
2. Check for adequate oil level.  
2. The engine may be in need of  
3. The battery voltage may be too  
mechanical repair. Check for  
low.  
spark and fuel.  
4. The fuel filter may be clogged or  
the fuel contaminated. Replace  
the fuel filter if necessary.  
The engine will not develop full 1. The fuel filter may be clogged or 1. Due to wear, the engine may  
power.  
the fuel contaminated. Replace  
the fuel filter if necessary.  
need major repair.  
2. The air filter may be clogged.  
Replace if necessary.  
3. The spark plug(s) may be faulty.  
Replace if necessary.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-10  
F-10  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine shuts down shortly 1. Check for adequate fuel supply 1. Check the RUN/STOP switch  
after starting.  
and a clean fuel filter.  
and associated leads for loose  
or faulty connections.  
2. Low oil level. Fill to proper  
level. Start engine and look for 2. The oil pressure switch may be  
leaks.  
faulty. Replace if necessary.  
3. Check the battery cables for  
loose or faulty connections.  
The engine will not idle down to low 1. Make sure the IDLER switch is 1. Check leads #210C and 215 for  
speed. The machine has normal  
weld output and auxiliary power.  
in the "AUTO" position.  
loose or faulty connections.  
See the Wiring Diagram.  
2. Make sure there is NOT an  
external load on the weld termi- 2. Perform the Idler Solenoid  
nals or the auxiliary power  
receptacles.  
Test.  
3. The Control Board may be  
faulty.  
3. Check for mechanical restric-  
tions in the idler solenoid link-  
age.  
The engine will not go to high idle 1. Make sure the auxiliary power 1. Make sure leads #3 and #6  
when using the auxiliary power.  
Auxiliary power is normal when the  
IDLER switch is in the "HIGH" posi-  
tion. Automatic idle function works  
properly when the welding termi-  
nals are loaded.  
leads are tight.  
pass through the toroid twice in  
opposite directions. See the  
Wiring Diagram.  
2. The automatic idler may not  
function if the auxiliary power is  
loaded to less than 100 watts.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-11  
F-11  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
ENGINE PROBLEMS  
The engine will not go to high idle 1. Make sure the welding cables 1. Check the Current Sensing  
when attempting to weld or when  
the auxiliary power is loaded.  
Welding output and auxiliary power  
outputs are normal when IDLER  
switch is in the " HIGH" position.  
and auxiliary power lead con-  
nections are tight.  
Toroid leads for loose or faulty  
connections. See the Wiring  
Diagram.  
2. The Current Sensing Toroid  
may be faulty.  
3. The Control Board may be  
faulty.  
The machine goes to low idle but 1. Make sure there is NOT an 1. The idler solenoid linkage may  
does not stay at low idle.  
external load (auxiliary or weld)  
connected to the Ranger 250.  
be misadjusted or damaged.  
2. The idler solenoid lead connec-  
tions (#210C and #215) may be  
loose or damaged.  
3. Perform the Idler Solenoid  
Test.  
4. The Control Board may be  
faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-12  
F-12  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
POSSIBLE AREAS OF  
RECOMMENDED  
(SYMPTOMS)  
MISADJUSTMENT(S)  
COURSE OF ACTION  
WELDING PROBLEMS  
The welding arc is “cold.” The 1. Check for loose or faulty con- 1. Check for the correct OCV at  
engine runs normally. The auxiliary  
power is normal.  
nections at the weld output ter-  
minals and welding cable con-  
nections.  
the welding output terminals. If  
the correct voltage is present at  
the output terminals, check for  
loose connections on the heavy  
current carrying leads inside the  
Ranger 250. See the Wiring  
Diagram.  
2. The welding cables may be too  
long or coiled, causing an  
excessive voltage drop.  
3. Make sure the electrode (wire,  
gas, voltage, current etc.) is  
correct for the process being  
used.  
2. If the OCV is low at the welder  
output terminals, perform the  
Engine Throttle Adjustment  
Test.  
3. Perform the Output Rectifier  
Bridge Test.  
4. Perform the Stator Voltage  
Test.  
5. Perform the Power Module  
Test.  
6. The Control Board may be  
faulty.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely,  
contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
1-800-833-9353.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-13  
F-13  
TROUBLESHOOTING & REPAIR  
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or 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.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This procedure will aid the technician in the removal and replacement of the case sheet  
metal cover and engine access doors.  
MATERIALS NEEDED  
3/8" Wrench or socket wrench  
9/16" Wrench  
This procedure should take approximately 15 minutes to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-14  
F-14  
TROUBLESHOOTING & REPAIR  
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)  
FIGURE F.1 – DOOR REMOVAL  
ENGINE  
ACCESS  
DOOR  
HINGES  
REMOVAL PROCEDURE  
1. Turn the engine off.  
8. Lift the case cover off the machine.  
2. Unlatch and open the engine service  
access doors.  
NOTE: It is not necessary to remove the gas  
cap in order to take the case cover off the  
machine. Leave the gas cap on when working  
on the Ranger 250.  
3. For each door, lift up on the stop pin and  
slide the door off the hinge. It may be nec-  
essary to lightly tap the door with a rubber  
mallet to free it from the hinge. See Figure  
F.1.  
REPLACEMENT PROCEDURE  
1. Install the right and left case sides and  
screw them in place.  
4. Using the 9/16" wrench, remove the  
exhaust pipe extension.  
2. Carefully set the case cover in place.  
Replace the lift bail cover seal.  
5. Remove the cover seal from around the lift  
bail.  
3. Install the exhaust pipe extension.  
6. Using the 3/8" wrench, remove the sheet  
metal and machine screws holding the case  
cover in place.  
4. Install the screws that hold the case cover  
in place.  
5. Install the doors by lifting the stop pins and  
sliding each door onto its hinges.  
7. Using the 3/8" wrench, remove the sheet  
metal screws from the right and left case  
sides. Tilt each side back and lift up to free  
the bottom tabs from their slots.  
6. Close and latch the doors.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-15  
F-15  
TROUBLESHOOTING & REPAIR  
POWER MODULE CAPACITOR DISCHARGE PROCEDURE  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or 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.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This procedure will insure that the large capacitors in the power module have been dis-  
charged. This procedure should be performed whenever work is to be attempted on or  
near the power module.  
MATERIALS NEEDED  
3/8" Wrench or socket wrench  
9/16" Wrench  
Volt/Ohmmeter  
Resistor (25-1000 ohms and 25 watts minimum)  
Jumper leads  
This procedure should take approximately 20 minutes to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-16  
F-16  
TROUBLESHOOTING & REPAIR  
POWER MODULE CAPACITOR DISCHARGE PROCEDURE (continued)  
FIGURE F.2 – POWER MODULE CAPACITOR TERMINAL DISCHARGE  
SHORT ACROSS  
TERMINALS  
WITH RESISTOR  
POWER  
MODULE  
CAPACITORS  
TEST PROCEDURE  
1. Turn the engine off.  
4. Using the resistor and jumper leads,  
CAREFULLY discharge the capacitor ter-  
2. Perform the Case Cover Removal proce-  
minals.  
NEVER USE A SHORTING  
dure.  
STRAP FOR THIS PURPOSE. DO NOT  
TOUCH THE TERMINALS WITH YOUR  
BARE HANDS. Repeat the procedure for  
the second capacitor.  
NOTE: It is not necessary to remove the gas  
cap in order to take the case cover off the  
machine. Be sure the gas cap is ON when dis-  
charging the power module capacitors.  
5. Using the volt/ohmmeter, check the voltage  
across the capacitor terminals. It should  
be zero volts.  
3. Locate the power module capacitors on the  
left side of the inner machine baffle. See  
Figure F.2.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-17  
F-17  
TROUBLESHOOTING & REPAIR  
IDLER SOLENOID TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or 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.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the idler solenoid is capable of functioning when it is energized  
with 12VDC.  
MATERIALS NEEDED  
3/8" Wrench or socket wrench  
9/16" Wrench  
External 12VDC supply (30 amps)  
Diagonal cutters  
Wiring Diagram  
Volt/Ohmmeter  
This procedure should take approximately 30 minutes to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-18  
F-18  
TROUBLESHOOTING & REPAIR  
IDLER SOLENOID TEST (continued)  
FIGURE F.3 – IDLER SOLENOID LEADS  
SOLENOID  
HOUSING  
LEADS #210C  
AND #215 TO  
CONNECTORS  
STATOR  
TEST PROCEDURE  
1. Turn the engine off.  
running and there is less resistance to  
solenoid movement) and check that it  
holds by itself. The solenoid should deac-  
tivate when the 12VDC is removed.  
2. Perform the Case Cover Removal proce-  
dure.  
3. Locate the idler solenoid mounted on the  
stator beside the fuel tank filler neck.  
7. If the solenoid does not operate properly,  
check for a mechanical restriction in the  
linkage. Also check for proper operation  
of the governor. See the Engine Owner's  
Manual.  
4. Locate and remove the two in-line connec-  
tors that attach the idler solenoid leads to  
the wiring harness leads (#210C and  
#215). Cut any necessary cable ties. See  
Figure F.3 and the Wiring Diagram.  
8. If the linkage is intact and the solenoid  
does not operate correctly when the  
12VDC is applied, the solenoid may be  
faulty. Replace.  
5. Check the coil resistance. The normal  
resistance is approximately 15 ohms. If the  
coil resistance is not correct, the solenoid  
may be faulty. Replace.  
9. Replace leads #210C and #215 to the  
correct in-line connectors. See Figure F.3  
and the Wiring Diagram. Replace any  
previously removed cable ties.  
6. Using the external 12VDC supply, apply  
12VDC to the solenoid leads. Push the  
solenoid plunger in (this simulates the  
action that takes place when the engine is  
10. If finished testing, perform the Case  
Cover Replacement procedure.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-19  
F-19  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or 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.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
If the machine output is low or high, this test will determine whether the engine is operat-  
ing at the correct speed (RPM) during both HIGH and LOW idle conditions. You can check  
RPM using a strobe-tach, a frequency counter, an oscilloscope or a vibratach. Directions  
for adjusting the throttle to the correct RPM are given.  
MATERIALS NEEDED  
3/8" Wrench or socket wrench  
9/16" Wrench  
White or red marking pencil  
Stobe-tach, frequency counter, oscilloscope, or vibratach  
This procedure should take approximately 35 minutes to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-20  
F-20  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.4 – STROBE MARK LOCATION  
MARK BLOWER  
PADDLE  
TEST PROCEDURE  
1. Turn the engine off.  
4. If either of the readings is incorrect, adjust  
the throttle as follows:  
2. Perform the Case Cover Removal proce-  
dure.  
Adjust HIGH IDLE: Use the 3/8" wrench to  
loosen the spring-loaded adjustment nut. See  
Figure F.5 for location of the adjustment nut.  
Turn the nut clockwise to increase the HIGH  
IDLE speed. Adjust the speed until the tach  
reads between 3700 and 3750 RPM.  
Strobe-Tach Method  
1. With a white or red marking pencil, place a  
mark on one of the blower paddles. See  
Figure F.4 for location.  
Adjust LOW IDLE: First make sure there is no  
load on the machine. Set the IDLER switch to  
AUTO and wait for the engine to change to low  
idle speed. Use the 7/16" wrench to adjust the  
solenoid nut, which changes the amount of throw  
in the throttle lever arm. See Figure F.6 for the  
location of the adjustment nut. Adjust the nut  
until the tach reads between 2350 and 2450  
RPM.  
2. Connect the strobe-tach according to the  
manufacturer's instructions.  
3. Start the engine and direct the strobe-tach  
light on the blower paddle. Synchronize it to  
the rotating mark.  
With the machine at HIGH IDLE the tach should  
read between 3700 and 3750 RPM.  
With the machine at LOW IDLE the tach should  
read between 2350 and 2450 RPM.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-21  
F-21  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.5 – HIGH IDLE ADJUSTMENT  
FIGURE F.6 – LOW IDLE ADJUSTMENT  
THROTTLE LINKAGE  
7/16" LOW IDLE  
ADJUSTMENT NUT  
3/8" HIGH IDLE  
ADJUSTMENT NUT  
SOLENOID  
HOUSING  
CHOKE CABLE  
MUFFLER  
ROD  
Frequency Counter Method  
Adjust HIGH IDLE: Use the 3/8" wrench to  
loosen the spring-loaded adjustment nut. See  
Figure F.5 for location of the adjustment nut.  
Turn the nut clockwise to increase the HIGH  
IDLE speed. Adjust the speed until the fre-  
quency reads between 61 and 63 Hz.  
1. Plug the frequency counter into one of the  
120 VAC auxiliary receptacles.  
2. Start the engine and check the frequency  
counter. At HIGH IDLE (3700 RPM), the  
counter should read between 61 and 63  
Hz. At LOW IDLE (2400 RPM), the counter  
should read between 39 and 40 Hz. Note  
that these are median measurements;  
hertz readings may vary slightly above or  
below.  
Adjust LOW IDLE: First make sure there is no  
load on the machine. Set the IDLER switch to  
AUTO and wait for the engine to change to low  
idle speed. Use the 7/16" wrench to adjust the  
solenoid nut, which changes the amount of  
throw in the throttle lever arm. See Figure F.6  
for the location of the adjustment nut. Adjust  
the nut until the frequency reads between 39  
and 40 Hz.  
3. If either of the readings is incorrect, adjust  
the throttle as follows:  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-22  
F-22  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
Oscilloscope Method  
Vibratach Method  
1. Connect the oscilloscope to the 120 VAC  
receptacle, according to the manufacturer's  
instructions. At HIGH IDLE (3700 RPM),  
the waveform should exhibit a period of  
16.2 milliseconds. At LOW IDLE (2400  
RPM), the waveform should exhibit a peri-  
od of 25.0 milliseconds. Refer to the NOR-  
MAL OPEN CIRCUIT VOLTAGE WAVE-  
FORM (120 VAC SUPPLY) HIGH IDLE -  
NO LOAD in this section of the manual.  
1. Place the vibratach as close to the engine  
as possible. With the machine case top  
removed, the top of the air cleaner is the  
best location.  
2. Start the engine and observe the whip han-  
dle of the vibratach. At HIGH IDLE (3700  
RPM), the whip handle should exhibit max-  
imum oscillation. At LOW IDLE (2400  
RPM), the whip handle should exhibit mini-  
mum oscillation. Note that these are medi-  
an measurements; vibratach readings may  
vary slightly above or below.  
2. If either of these waveform periods is incor-  
rect, adjust the throttle as follows:  
Adjust HIGH IDLE: Use the 3/8" wrench to  
loosen the spring-loaded adjustment nut. See  
Figure F.5 for location of the adjustment nut.  
Turn the nut clockwise to increase the HIGH  
IDLE speed. Adjust the speed until the period  
is 16.2 milliseconds.  
3. If either of the vibratach indications is incor-  
rect, adjust the throttle as follows:  
Adjust HIGH IDLE: Use the 3/8" wrench to turn  
the spring-loaded adjustment nut. See Figure  
F.5 for location of the adjustment nut. Turn the  
nut clockwise to increase HIGH IDLE speed.  
Adjust the speed until the vibratach whip han-  
dle exhibits maximum oscillation at 3650 to  
3750 RPM.  
Adjust LOW IDLE: First make sure there is no  
load on the machine. Set the IDLER switch to  
AUTO and wait for the engine to change to low  
idle speed. Use the 7/16" wrench to adjust the  
solenoid nut, which changes the amount of  
throw in the throttle lever arm. See Figure F.6  
for the location of the adjustment nut. Adjust  
the nut until the period is 25.0 milliseconds.  
Adjust LOW IDLE: First make sure there is no  
load on the machine. Set the IDLER switch to  
AUTO and wait for the engine to change to low  
idle speed. Use the 7/16" wrench to adjust the  
solenoid nut, which changes the amount of  
throw in the throttle lever arm. See Figure F.6  
for location of the adjustment nut. Adjust the  
speed until the vibratach whip handle exhibits  
minimum oscillation at 2350 to 2450 RPM.  
When finished testing, perform the Case Cover  
Replacement procedure.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-23  
F-23  
TROUBLESHOOTING & REPAIR  
ROTOR RESISTANCE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or 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.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if there is an open winding in the rotor or if the rotor is grounded.  
MATERIALS NEEDED  
Ohmmeter  
3/8" Wrench or socket wrench  
7/16" wrench  
9/16" Wrench  
Needle nose pliers  
Wiring Diagram  
This procedure should take approximately 30 minutes to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-24  
F-24  
TROUBLESHOOTING & REPAIR  
ROTOR RESISTANCE TEST (continued)  
FIGURE F.7 – ROTOR BRUSH LEADS  
SLIP RINGS  
BRUSHES  
LEADS  
200A  
200  
LEADS  
201  
5H  
+
-
TEST PROCEDURE  
1. Turn the engine off.  
5. Measure the resistance to ground. Place  
one meter probe on either of the slip rings.  
Place the other probe on any good unpaint-  
ed ground. The resistance should be very  
high, at least 500,000 ohms.  
2. Perform the Case Cover Removal proce-  
dure.  
3. Locate and label the four leads from the rotor  
brush holder assembly. See Figure F.7.  
Using the needle nose pliers, remove the  
leads. See Figure F.7. This will electrically  
isolate the rotor windings.  
6. If the test does not meet the resistance spec-  
ifications, then the rotor may be faulty.  
Replace.  
7. Connect the leads previously removed from  
the brush assembly. Make sure the leads  
are connected to the proper brushes. See  
the Wiring Diagram.  
4. Using the ohmmeter, check the rotor winding  
resistance across the slip rings. See Figure  
F.7. Normal resistance is approximately 4.7  
ohms.  
8. If finished testing, perform the Case Cover  
Replacement procedure.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-25  
F-25  
TROUBLESHOOTING & REPAIR  
FLASHING AND ROTOR VOLTAGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or 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.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the correct DC voltage is being applied to the rotor at the maxi-  
mum engine speed (3700 RPM). This information will aid the technician in determining if  
the generator field is operating properly. Tests can be conducted with the engine stopped  
(static test) and running (dynamic test). These procedures also allow you to test the oil  
pressure switch for proper functioning.  
MATERIALS NEEDED  
3/8" Wrench or socket wrench  
9/16" Wrench  
Test pins  
Jumper lead  
Volt/Ohmmeter  
Wiring Diagram  
This procedure should take approximately 35 minutes to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-26  
F-26  
TROUBLESHOOTING & REPAIR  
FLASHING AND ROTOR VOLTAGE TEST (continued)  
FIGURE F.8 – ROTOR BRUSH LEADS  
SLIP RINGS  
BRUSHES  
LEADS  
200A  
200  
LEADS  
201  
5H  
+
-
TEST PROCEDURE  
1. Perform the Case Cover Removal proce-  
d. Connect the negative meter probe to the  
other brush (leads #201 and #5H).  
dure.  
2. Set the volt/ohmmeter to the DC volts posi-  
tion.  
e. Measure the voltage. It should read  
between 3.0 and 4.0 VDC.  
3. Test rotor voltage - static (engine stopped  
but running condition simulated):  
f. Set the RUN/STOP switch to STOP.  
Oil Pressure Switch Test  
a. Connect a jumper between P51 leads  
#210 and #224.  
See the Wiring  
The oil pressure switch is designed to open if it  
detects low or no oil pressure. If you can con-  
duct the test described here in Step 3 and  
obtain the 3.0 to 4.0 VDC voltage reading,  
WITHOUT THE JUMPER, then the oil pressure  
switch or the Battery PC board may be faulty.  
Diagram. This bypasses the oil pressure  
switch and simulates the test with the  
engine running.  
b. Remove the spark plug wires, then set  
the RUN/STOP switch to RUN.  
c. Connect the positive meter probe to the  
brush nearest the rotor lamination (leads  
#200A and #200). See Figure F.8 for  
location.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-27  
F-27  
TROUBLESHOOTING & REPAIR  
FLASHING AND ROTOR VOLTAGE TEST (continued)  
FIGURE F.9 – FIELD DIODE RECTIFIER BRIDGE AND FILTER CAPACITOR  
7
201  
201A  
9
200A  
200B  
FIELD  
RECTIFIER  
BRIDGE  
RETAINING  
TAB  
CABLE  
CAPACITOR  
4. Test rotor voltage - dynamic (engine run-  
ning)  
5. If the voltage reading is low or not present,  
the generator field is not functioning prop-  
erly. Perform the Rotor Resistance Test.  
Also check the field diode rectifier bridge,  
filter capacitor, and associated leads and  
connections. See Figure F.9 for location.  
See the Wiring Diagram.  
a. Remove the jumper used in the previous  
step. Replace the spark plug wires, set  
the RUN/STOP switch to RUN, start the  
engine and run it at high idle speed  
(3700 RPM).  
6. Check the rotor ground wire #5H for good  
connection. See the Wiring Diagram.  
b. Connect the positive meter probe to the  
brush nearest the rotor lamination (leads  
#200A and #200). See Figure F.8 for  
location.  
7. If the rotor voltage readings are normal, the  
field circuit is functioning properly.  
c. Connect the negative meter probe to the  
other brush (leads #201 and #5H).  
8. If finished testing, perform the Case Cover  
Replacement procedure.  
d. Carefully measure the voltage. It should  
read approximately 46 - 52 VDC.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-28  
F-28  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TESTS  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or 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.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the correct AC voltages are being generated from the stator  
windings.  
MATERIALS NEEDED  
3/8" Wrench or socket wrench  
9/16" Wrench  
3/4" Wrench  
Test pins  
Volt/Ohmmeter  
Wiring Diagram  
This procedure should take approximately 40 minutes to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-29  
F-29  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TESTS (continued)  
FIGURE F.10 – RECEPTACLE LEAD LOCATIONS  
GND M  
GND L  
GND J  
GND G  
GND D  
GND C  
GND B  
20 AMP  
3A  
50 AMP  
3
3A  
25 AMP  
GND A  
3D  
GND C  
AMPHENOL 1  
209  
AMPHENOL 2  
C
GOLD  
J102  
31  
5
5A  
5B  
5C  
5F  
5G  
5H  
5K  
5L  
CB7  
CB1  
CB5  
3E  
C
B
A
212A  
212  
3D, 32  
J100  
120/240 V AC  
B
D
D
SILVER  
5A  
L
6F  
K
3E  
J
GND G  
GND D  
E
A
M
E
N
6
6B  
CB6  
I
6B  
42  
CB8  
42A  
15 AMP  
F
F
6E  
G
H
CB2  
GND E  
GOLD  
KEY  
5C  
6F  
J101  
6E  
KEY  
SILVER  
5B  
50 AMP  
20 AMP  
208  
SHUNT  
208A  
208B  
206A  
206B  
POSITIVE PUTPUT STID  
NEGATIVE PUTPUT STUD  
204S 206S  
CASE FRONT - REAR VIEW  
TEST PROCEDURE  
For all tests: Perform the Case Cover Removal  
To test the 240 VAC winding:  
procedure.  
1. Connect the volt/ohmmeter probes to leads  
#6F and #3E where they connect to the  
240VAC receptacle.  
To test the 120 VAC winding:  
1. Connect the volt/ohmmeter probes to either  
120 VAC receptacle as follows. See Figure  
F.10 and the Wiring Diagram.  
NOTE: It is easier to insert the probes directly  
into the receptacle to perform this test. However,  
the probes may not reach in far enough to make  
or keep a good connection. In this case, before  
you start the engine, insert two test pins into the  
receptacle. Hold the test probes against these  
inserts to measure voltage (Step 3).  
Upper receptacle, to leads #3D and #5A.  
Lower receptacle, to leads #6E and 5B.  
NOTE: It is easier to insert the probes directly  
into the receptacle to perform this test. However,  
the probes may not reach in far enough to make  
or keep a good connection. In this case, before  
you start the engine, insert two test pins into the  
receptacle. Hold the test probes against these  
inserts to measure voltage (Step 3).  
2. Start the engine and run it at high idle (3700  
RPM).  
3. Check the AC voltage reading. It should read  
between 236 and 252 VAC.  
2. Start the engine and run it at high idle (3700  
RPM).  
3. Check the AC voltage reading. It should read  
between 118 and 126 VAC.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-30  
F-30  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TESTS (continued)  
FIGURE F.11 – LOCATION OF LEADS #7 AND #9 AT FIELD DIODE RECTIFIER BRIDGE  
201  
201A  
7
_
AC  
200A  
200B  
+
9
AC  
7
201  
201A  
9
200A  
200B  
FIELD  
RECTIFIER  
BRIDGE  
RETAINING  
TAB  
CABLE  
CAPACITOR  
To test the field winding:  
ken wires between the test points and the stator  
windings. See the Wiring Diagram. Make sure  
that the windings are NOT grounded internally to  
the stator iron. If the leads are intact, then the  
stator may be faulty. Replace the stator.  
1. Connect the volt/ohmmeter probes to leads  
#7 and #9 where they connect to the field  
diode rectifier bridge. See Figure F.11.  
2. Start the engine and run it at high idle (3700  
RPM).  
If the voltage readings are within specifications,  
then the windings are good and functioning prop-  
erly.  
3. Check the AC voltage reading. It should be  
between 40 and 50 VAC.  
4. If finished testing, perform the Case Cover  
If any one or more of the readings are missing or  
not within specifications, check for loose or bro-  
Replacement procedure.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-31  
F-31  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TESTS (continued)  
FIGURE F.12 – 14-PIN AMPHENOL PIN ASSIGNMENTS  
C
Y
B
D
Z
L
E
K
A
M
J
W
N
I
F
G
X
H
To test the feeder winding:  
4. Connect the volt/ohmmeter probes to leads  
#41A and #42A where they connect to circuit  
breaker CB8 and the 14-pin amphenol. See  
the Wiring Diagram.  
1. Connect the volt/ohmmeter probes to leads  
#31 and #32 where they connect to circuit  
breaker CB1 and the 14-pin amphenol. See  
the Wiring Diagram.  
NOTE: It is possible to check this voltage reading  
at the amphenol by inserting the test probe pins  
at pin K (for lead #42A) and pin I (for lead #41A).  
See Figure F.12. However, if you use this method  
and you get no voltage reading, it could mean  
there is a break or loose connection in the leads  
between the circuit breaker and the amphenol.  
Check the reading again with one probe at the  
circuit breaker connection for lead #42A and the  
other probe at amphenol pin I.  
NOTE: It is possible to check this voltage reading  
at the amphenol by inserting the test probe pins  
at pin A (for lead #32) and pin J (for lead #31).  
See Figure F.12. However, if you use this method  
and you get no voltage reading, it could mean  
there is a break or loose connection in the leads  
between the circuit breaker and the amphenol.  
Check the reading again with one probe at the  
circuit breaker connection for lead #32 and the  
other probe at amphenol pin J.  
5. Start the engine and run it at high idle (3700  
RPM).  
2. Start the engine and run it at high idle (3700  
RPM).  
6. Check the AC voltage reading. It should be  
between 40 and 46 VAC.  
3. Check the AC voltage reading. It should be  
between 118 and 126 VAC.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-32  
F-32  
TROUBLESHOOTING & REPAIR  
STATOR VOLTAGE TESTS (continued)  
FIGURE F.13 – OUTPUT RECTIFIER BRIDGE CONNECTIONS  
TOP  
OUTPUT  
RECTIFIER  
BRIDGE  
W1  
W2  
W3  
CENTER  
BOTTOM  
W6  
W7  
W11  
W4  
W5  
W10  
W8  
W9  
CHOKE  
If any one or more of the readings are missing or  
not within specifications, then check for loose or  
broken wires between the test points and the sta-  
tor windings. See the Wiring Diagram. Make  
sure that the windings are NOT grounded inter-  
nally to the stator iron. If the leads are intact,  
then the stator may be faulty. Replace the stator.  
2. Check for approximately 58 - 65 VAC from  
W1 to W2. Also check for the same voltage  
from W2 to W3 and from W1 to W3.  
3. If any of these voltages are low or missing,  
perform the Flashing and Rotor Voltage  
Test and also the Rotor Resistance Test.  
4. If the tests in Step 2 are OK and the stator  
voltages are low or missing, the stator may  
be faulty.  
If the voltage readings are within specifications,  
then the windings are good and functioning prop-  
erly.  
5. If finished testing, perform the Case Cover  
7. If finished testing, perform the Case Cover  
Replacement procedure.  
Replacement procedure.  
To test the stator weld windings:  
1. Locate the weld winding leads connected to  
the three-phase output rectifier bridge. See  
Figure F.13.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-33  
F-33  
TROUBLESHOOTING & REPAIR  
ANALOG POWER PC BOARD VOLTAGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or 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.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if the Analog Power PC board is receiving and passing the prop-  
er signal voltages.  
MATERIALS NEEDED  
Analog Volt/Ohmmeter  
3/8" Wrench or Socket Wrench  
9/16" Wrench  
Wiring Diagram  
This procedure should take approximately 30 minutes to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-34  
F-34  
TROUBLESHOOTING & REPAIR  
ANALOG POWER PC BOARD VOLTAGE TEST (continued)  
FIGURE F.14 – ANALOG POWER PC BOARD  
RESISTOR R3  
(0N BLOWER  
SIDE OF  
C1  
BAFFLER)  
C2  
PCB5  
BY-PASS  
PC BOARD  
PCB2  
ANALOG POWER  
PC BOARD  
1
J41  
13 1J41 to POS TERMINAL ON C2 - 85V SUPPLY  
14 2J41 to NEG TERMINAL ON C2 - 85V SUPPLY  
CONTROL CIRCUIT  
INPUT POWER  
J60  
1
J61  
1
3 1  
1
2
4
J42  
J62  
1
J41  
GND K  
GND L  
6
7
8
9
10  
1
2
3
4
5
J42  
BLOWER BAFFLE - SIDE OPPOSITE BLOWER  
TEST PROCEDURE  
1. Turn the engine off.  
If the reading is not correct, the stator output may  
be incorrect, the rectifier output may be incorrect,  
the capacitors may be faulty or the Power Module  
PC board may be faulty. Perform the Stator  
Voltage Test, the Output Rectifier Bridge Test,  
and the Power Module PC Board Test. The  
capacitors C1 and C2 may be faulty. Test and  
replace if necessary.  
2. Perform the Case Cover Removal proce-  
dure.  
3. Locate plugs J41 and J42 from the Analog  
Power PC board. See Figure F.14.  
4. Start the engine and run it at high idle (3700  
RPM) with no load.  
6. Check for the correct output voltage readings  
per Table F.1. If any of the readings are not  
correct, the Analog Power PC board may be  
faulty.  
5. Check for the correct Analog Power PC  
board input voltage:  
a. Set the volt/ohmmeter to the Volts DC  
position.  
b. Place the negative probe on J41 pin 2 and  
the positive probe on J41 pin 1.  
c. The reading should be between 75 and 85  
VDC.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-35  
F-35  
TROUBLESHOOTING & REPAIR  
ANALOG POWER PC BOARD VOLTAGE TEST (continued)  
TABLE F.1. – ANALOG PC BOARD OUTPUT VOLTAGE TABLE  
TEST POINTS  
COMPONENT TESTED  
VOLTAGE READING  
1J42 to 6J42  
2J42 to 7J42  
5J42 to 7J42  
9J42 to 7J42  
10J42 to 4J42  
Chopper Power Supply  
+20 VDC  
+5 VDC  
Weld Control PC Board Power Supply  
Weld Control PC Board Power Supply  
Weld Control PC Board Power Supply  
Weld Control PC Board Power Supply  
+15 VDC  
-15 VDC  
+15 VDC  
7. If finished testing, perform the Case Cover  
Replacement procedure.  
NOTE ON THE BYPASS PC BOARD  
The purpose of the Bypass PC board circuitry is  
to provide a more attractive path to ground for  
transient spikes and high frequency signals that  
could damage sensitive circuit components. The  
Ranger 250 Bypass PC board cannot be tested.  
However, a faulty Bypass PC may show visible  
physical damage. As a general rule of practice, if  
you have catastrophic damage to any other PC  
board on the machine, the Bypass PC board  
should be replaced as well.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-36  
F-36  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or 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.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if there are faulty diodes in the output rectifier bridge.  
MATERIALS NEEDED  
Volt/Ohmmeter (Analog)  
11/32" Nut driver  
1/2" Wrench  
3/8" Wrench or socket wrench  
9/16" Wrench  
Wiring Diagram  
This procedure should take approximately 45 minutes to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-37  
F-37  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST (continued)  
FIGURE F.15 – PLUG J41 AND RESISTOR R3 LOCATIONS  
RESISTOR R3  
(0N BLOWER  
SIDE OF  
C1  
BAFFLER)  
C2  
PCB5  
BY-PASS  
PC BOARD  
PCB2  
ANALOG POWER  
PC BOARD  
1
13 1J41 to POS TERMINAL ON C2 - 85V SUPPLY  
14 2J41 to NEG TERMINAL ON C2 - 85V SUPPLY  
CONTROL CIRCUIT  
INPUT POWER  
J41  
J60  
1
J61  
1
3 1  
1
2
4
J42  
J62  
1
J41  
GND K  
GND L  
6
7
8
9
10  
1
2
3
4
5
11 1J42 toPIN 3 of P50  
105A 2J42 to3J13  
5L 4J42 to GND. SCREW  
115A 5J42 to 1J13  
12 6J42 to PIN 1 of P50  
101A 7J42 to 2J13  
116A 9J42 to 4J13  
CHOPPER POWER SUPPLY, 20V  
WELD BOARD POWER SUPPLY, +5V TO CIRCUIT GROUND  
FRAME GROUND  
WELD BOARD POWER SUPPLY, +15V TO CIRCUIT GROUND  
CHOPPER POWER SUPPLY, 20V  
CIRCUIT GROUND  
WELD BOARD POWER SUPPLY, -15V TO CIRCUIT GROUND  
WELD BOARD POWER SUPPLY, +15V TO CASE GROUND  
118A 10J42 to 5J13  
J42  
BLOWER BAFFLE - SIDE OPPOSITE BLOWER  
TEST PROCEDURE  
1. Turn the engine off.  
4. Disconnect plug J41 (with leads #13 and  
#14) from the Analog Power PC board. See  
Figure F.15.  
2. Perform the Case Cover Removal proce-  
dure.  
5. If your machine has resistor R3, with the  
11/32" nut driver, disconnect one end of  
resistor R3, either lead #252 or #253. See  
Figure F.15.  
3. Perform the Power Module Capacitor  
Discharge procedure.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-38  
F-38  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE TEST (continued)  
FIGURE F.16 – OUTPUT RECTIFIER BRIDGE LEAD REMOVAL AND TEST POINTS  
TOP  
OUTPUT  
RECTIFIER  
BRIDGE  
W1  
W2  
W3  
CENTER  
BOTTOM  
CHOKE  
6. Electrically isolate the output rectifier bridge:  
Using the 1/2" wrench, remove stator leads  
W1, W2, and W3 from their bolted connec-  
tions on the left side of the bridge. Note lead  
placement for reassembly. Bend the leads  
out into "free air" so that they do not touch  
anything. See Figure F.16.  
When all tests are complete:  
1. Replace stator leads W1, W2, and W3 to  
their respective terminals. Replace lead(s)  
#252 or #253 previously removed. See  
Figure F.16.  
2. If finished testing, perform the Case Cover  
Replacement procedure.  
7. Remove any load that may be connected to  
the weld output terminals.  
8. Check all diode assemblies individually for  
opens or shorts. If any of the checks are not  
correct, the output rectifier bridge may be  
faulty. See the Output Rectifier Bridge  
Removal and Replacement procedure.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-39  
F-39  
TROUBLESHOOTING & REPAIR  
POWER MODULE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-  
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will help determine if the power module is shorted. This is a resistance test, not a  
voltage test. This test will only help diagnose a problem in the "power" section of the module.  
Other PC board components could be faulty.  
MATERIALS NEEDED  
Volt/Ohmmeter (Analog)  
3/8" Wrench or socket wrench  
9/16" Wrench  
1/2" Wrench  
7/16" Wrench  
This procedure should take approximately 45 minutes to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-40  
F-40  
TROUBLESHOOTING & REPAIR  
POWER MODULE TEST (continued)  
FIGURE F.17 – POWER MODULE CONNECTIONS  
TEMPERATURE  
SWITCH  
POSITIVE (+)  
STRAP  
W8  
W9  
W6  
POWER  
MODULE  
PC BOARD  
POSITIVE (+)  
STRAP  
TEST PROCEDURE  
1. Turn the engine off.  
6. Using the 7/16" wrench, remove the two pos-  
itive jumper straps attaching the capacitors to  
the Power Module PC board. Note all lead  
placements for reassembly. Note lead #253,  
#13, W4 and W5 do not have to be removed  
from the circuit. See the Wiring Diagram.  
The small flex lead connected to D4 should  
be removed and electrically isolated.  
2. Perform the Case Cover Removal proce-  
dure.  
3. Perform the Power Module Capacitor  
Discharge procedure.  
4. Using the 7/16" wrench, loosen the nuts on  
the positive terminals of the power capaci-  
tors. Then remove the nuts, lock washers,  
and flat washers from the terminals where  
the positive straps connect to the Power  
Module PC board. Flip the straps out of the  
way. See Figure F.17.  
7. Using the 7/16" wrench, remove the W6 lead  
strap from the power module (two bolted con-  
nections). Suggestion: First loosen the  
straps at the capacitor terminals and remove  
the nuts on the power module. Then fold the  
straps back out of the way.  
5. Using the 7/16" wrench, remove the flex  
leads W8 and W9 from the Power Module PC  
board terminals.  
NOTE: Make sure the bolts do not fall back  
against the heat sink.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-41  
F-41  
TROUBLESHOOTING & REPAIR  
POWER MODULE TEST (continued)  
FIGURE F.18 – IGBT TEST  
HEAT SINK  
POSITIVE (+)  
CAPACITOR  
TERMINAL  
CONNECTIONS  
Check IGBT for “Shorts”  
8. Using the analog ohmmeter, connect the  
positive meter probe to the heat sink and the  
negative meter probe to the positive capaci-  
tor terminal on the power module chopper  
PC board. See Figure F.18. The resistance  
reading should be high (over 20,000 ohms).  
9. Reverse the meter probe leads. The resis-  
tance should be very high (over 20,000  
ohms). It the resistance is low in either Step  
8 or 9, the IGBT may be shorted or leaky.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-42  
F-42  
TROUBLESHOOTING & REPAIR  
POWER MODULE TEST (continued)  
FIGURE F.19 – DIODE MODULE TEST  
HEAT SINK  
DIODE  
MODULE  
TERMINALS  
Check Diode Module  
10. Using the analog ohmmeter, connect the  
negative meter probe to the terminal on the  
diode module. See Figure F.19. Connect the  
positive meter probe to the heat sink. The  
resistance should be very high (over 20,000  
ohms).  
When all tests are complete:  
1. Reconnect all leads previously removed.  
2. Torque the capacitor nuts to 50-60 inch-  
pounds.  
3. If finished testing, perform the Case Cover  
11. Using the analog ohmmeter, connect the  
positive meter probe to the terminal on the  
diode module. Connect the negative meter  
probe to the heat sink. The resistance should  
be lower (approximately 300 ohms). Also  
check diode D4 for shorted or open condition.  
See the Wiring Diagram.  
Replacement procedure.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-43  
F-43  
TROUBLESHOOTING & REPAIR  
FLYWHEEL ALTERNATOR TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-  
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
DESCRIPTION  
This test will help determine if the flywheel alternator is properly charging the battery.  
MATERIALS NEEDED  
Volt/Ohmmeter  
3/8" Wrench or socket wrench  
This procedure should take approximately 15 minutes to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-44  
F-44  
TROUBLESHOOTING & REPAIR  
FLYWHEEL ALTERNATOR TEST (continued)  
FIGURE F.20 – PLUG J51 PIN LOCATION  
210 (TO  
RUN-STOP  
SWITCH)  
221 (TO  
RUN-STOP  
SWITCH)  
BATTERY  
CHARGER  
3
4
1
2
TO OIL  
PRESSURE  
SWITCH  
IGNITION GROUND  
TO STOP ENGINE  
BATTERY  
212A (TO BATTERY  
CHARGER CIRCUIT  
BREAKER)  
211A (TO START  
BUTTON SWITCH)  
225 (TO BATTERY  
PC BOARD)  
TO FUEL  
SHUTOFF  
SOLENOID  
3
4
1
2
3
4
1
2
3
1
2
IGNITION  
CIRCUIT +12V  
224 (TO HOUR  
METER POS.)  
212A (TO BATTERY  
CHARGER CIRCUIT  
BREAKER)  
4
CHARGER  
224A  
WELDER HARNESS SIDE  
LEAD ENTRY VIEW  
ENGINE SIDE  
LEAD ENTRY VIEW  
WELDER HARNESS SIDE  
LEAD ENTRY VIEW  
ENGINE SIDE  
LEAD ENTRY VIEW  
ENGINE CONNECTOR BLOCK J51  
KOHLER CH20 ENGINE  
ENGINE CONNECTOR BLOCK J51  
ONAN P216 ENGINE  
TEST PROCEDURE  
1. Turn the engine off.  
5. Perform the Case Cover Removal proce-  
dure.  
2. Using the 3/8" wrench, remove the three  
screws holding the battery access cover in  
place and slide the battery tray out enough to  
access the terminals. Using the volt/ohmme-  
ter measure the voltage at the battery termi-  
nals. It should be approximately 12 volts DC.  
6. Perform the Power Module Capacitor  
Discharge procedure.  
7. Locate plug J51 leads 212A (pin 3 or 2) or  
engine alternator lead pin 3 (C1). See Figure  
F.20. Check from pin 3 to the negative bat-  
tery terminal with the engine running at high  
idle speed (3700 RPM). Normal voltage is  
13.7 to 14.2 volts DC. If not correct, the fly-  
wheel alternator may be faulty. If correct,  
check the wiring between the flywheel alter-  
nator and the positive battery terminal. See  
the Wiring Diagram.  
3. Start the engine and run it at high idle for  
approximately 30 seconds. Measure the  
voltage at the battery terminals. It should be  
13.7 to 14.2 volts DC. If correct, the test is  
over. If not correct, proceed to the next step.  
4. Check circuit breaker CB7 on the front panel.  
Reset if tripped. Repeat Step 3. If circuit  
breaker is functioning properly, proceed to  
Step 5.  
8. If finished testing, perform the Case Cover  
Replacement procedure.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-45  
F-45  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (120VAC SUPPLY)  
HIGH IDLE – NO LOAD  
16.2 ms  
0 volts  
50V  
5ms  
This is the typical auxiliary output  
voltage generated from a properly  
operating machine. Note that each  
vertical division represents 50 volts  
and that each horizontal division rep-  
resents 5 milliseconds in time.  
NOTE: Scope probes are connected  
at machine 120 VAC receptacle.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-46  
F-46  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (STICK)  
MAX CONTROL POT - HIGH IDLE - NO LOAD  
CH1  
0 volts  
50V  
5ms  
This is the typical DC open circuit out-  
put voltage generated from a properly  
operating machine. Note that each  
vertical division represents 50 volts  
and that each horizontal division rep-  
resents 5 milliseconds in time.  
NOTE: Scope probes are connected  
at weld output terminals.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-47  
F-47  
TROUBLESHOOTING & REPAIR  
NORMAL WELD VOLTAGE WAVEFORM (STICK CC)  
MACHINE LOADED TO 250 AMPS AT 25 VOLTS  
Trig +15V  
CH1  
0 volts  
20V  
1ms  
This is the typical DC open circuit out-  
put voltage generated from a properly  
operating machine. Note that each  
vertical division represents 20 volts  
and that each horizontal division rep-  
resents 1 millisecond in time.  
The machine was loaded with a resis-  
tance grid bank to 250 amps at 25  
volts.  
NOTE: Scope probes are connected  
at weld output terminals.  
SCOPE SETTINGS  
Volts/Div .....................20V/Div  
Horizontal Sweep.....1 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-48  
F-48  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (WIRE CV TAP)  
MAX CONTROL POT - HIGH IDLE - NO LOAD  
0 volts  
50V  
5ms  
This is the typical DC open circuit out-  
put voltage generated from a properly  
operating machine. Note that each  
vertical division represents 50 volts  
and that each horizontal division rep-  
resents 5 milliseconds in time.  
NOTE: Scope probes are connected  
at weld output terminals.  
SCOPE SETTINGS  
Volts/Div.....................50V/Div.  
Horizontal Sweep.....5 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-49  
F-49  
TROUBLESHOOTING & REPAIR  
NORMAL WELD VOLTAGE WAVEFORM (WIRE CV)  
MACHINE LOADED TO 250 AMPS AT 28 VOLTS  
0 volts  
20V  
1ms  
This is the typical DC voltage gener-  
ated from a properly operating  
machine. Note that each vertical divi-  
sion represents 20 volts and that  
each horizontal division represents 1  
millisecond in time.  
The machine was loaded with a resis-  
tance grid bank to 250 amps at 28  
volts.  
NOTE: Scope probes are connected  
at weld output terminals.  
SCOPE SETTINGS  
Volts/Div.....................20V/Div.  
Horizontal Sweep.....1 ms/Div.  
Coupling.............................DC  
Trigger.........................Internal  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-50  
F-50  
TROUBLESHOOTING & REPAIR  
POWER MODULE ASSEMBLY/POWER MODULE PC BOARD/  
DIODE MODULE REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician  
or 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.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 1-800-833-9353 (WELD).  
DESCRIPTION  
This procedure will aid the technician in the removal and replacement of the Power  
Module assembly. Procedures for removal and replacement of the Power Module PC  
board and the diode module are included.  
MATERIALS NEEDED  
3/8" wrench or socket wrench  
7/16" wrench  
7/16" Socket wrench  
1/2" Wrench  
9/16" Wrench  
3/16" Allen head wrench  
9/64" Allen head wrench  
Torque wrench with 3/16" and 9/64" allen head sockets  
Phillips head screw driver  
Diagonal cutters  
Electrical thermal joint compound - Penetrox A-13  
This procedure should take approximately 1 hour to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-51  
F-51  
TROUBLESHOOTING & REPAIR  
POWER MODULE ASSEMBLY  
REMOVAL AND REPLACEMENT  
FIGURE F. 21 – POWER MODULE CONNECTIONS  
TEMPERATURE  
SWITCH  
POSITIVE (+)  
STRAP  
W8  
W9  
W6  
POWER  
MODULE  
PC BOARD  
POSITIVE (+)  
STRAP  
PROCEDURE  
5. Using the 7/16" wrench, loosen the nuts on  
the positive terminals of the power capaci-  
tors. Then remove the nuts, lock washers,  
and flat washers from the terminals where  
the positive straps connect to the Power  
Module PC board. Flip the straps out of the  
way.  
Removal  
Refer to Figures F.21 and F.22.  
1. Turn the engine off.  
2. Perform the Case Cover Removal proce-  
dure.  
6. Using the 7/16" wrench, loosen the center  
nut on the negative strap. Using the 7/16"  
wrench, remove the two bolts, lock washers  
and flat washers from the diode module.  
Remove the strap.  
3. Perform the Power Module Capacitor  
Discharge procedure.  
4. Label heavy leads W8 and W9 and, using the  
7/16" wrench, remove the nuts, lock washers,  
and flat washers holding them to the Power  
Module PC board.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-52  
F-52  
TROUBLESHOOTING & REPAIR  
POWER MODULE ASSEMBLY  
REMOVAL AND REPLACEMENT (continued)  
7. Label and remove leads #232 and #233  
from the temperature switch.  
4. Using the 7/16" wrench, attach the negative  
strap from the power capacitors to the diode  
module with two bolts, lock washers, and flat  
washers. Using the 7/16" wrench, tighten the  
negative strap center nut. Tighten all fasten-  
ers to 30-40 in-lbs.  
8. Unscrew plug J50 from the vertical baffle.  
Using the phillips head screw driver,  
remove the four screws holding the plug to  
the vertical baffle. Cut any necessary cable  
ties. Then pull the plug and leads away  
from the baffle.  
5. Using the 7/16" wrench, attach the positive  
straps from the power capacitors to the  
Power Module PC board. Tighten the fasten-  
ers at the positive terminals of the power  
capacitors to between 50 and 60 in-lbs.  
9. Using the 3/8" socket wrench, remove the  
three screws holding the Power Module  
heat sink to its brackets on the vertical baf-  
fle. Remove the glastic fan guard, if present  
on your machine.  
6. Mount heavy leads W8 and W9 to the Power  
Module PC board with the 7/16" nuts, lock  
washers, and flat washers. Apply a thin coat-  
ing of electrical thermal joint compound  
(Penetrox A-13) to the mating surfaces (but  
not the threads). Tighten the fasteners to  
between 12 and 18 in-lbs).  
10. Remove the Power Module assembly from  
the machine.  
Replacement  
Refer to Figures F.21 and F.22.  
7. Replace any cable ties cut at disassembly.  
1. Mount the heat sink to the brackets on the  
vertical baffle with the three 3/8" screws.  
Mount the glastic fan guard, if present.  
See the procedures below for removal and  
replacement of the power module PC board and  
diode module. When procedures are complete,  
perform the Case Cover Replacement proce-  
dure.  
2. Mount plug J50 to the vertical baffle with  
four phillips head screws. Connect the plug  
and screw it together.  
3. Install leads #232 and #233 to the tempera-  
ture switch.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-53  
F-53  
TROUBLESHOOTING & REPAIR  
POWER MODULE PC BOARD REMOVAL AND REPLACEMENT  
FIGURE F.22 – DIODE MODULE/POWER MODULE ASSEMBLY DETAILS  
PLUG J50  
POWER  
MODULE  
PC BOARD  
ALLEN HEAD  
SCREWS (4)  
DIODE MODULE  
COPPER  
SPACERS  
HEAT SINK  
TEMPERATURE  
SWITCH  
Removal  
Replacement  
1. Perform steps #1 through #6 and #8 from the  
Power Module Assembly Removal proce-  
dure.  
1. Make sure the mating surfaces between the  
copper spacers and the heat sink are clean,  
dry, and free of grease.  
2. Using the 3/16" allen wrench, remove the  
four screws and lock washers holding the  
board to the heat sink. Note the two copper  
spacers for the center terminals for reassam-  
bly. See Figure F.22.  
2. Apply a thin coating of electrical thermal joint  
compound (Penetrox A-13) to the mating sur-  
faces between the copper spacers and the  
heat sink.  
3. Using the torque wrench and 3/16" allen head  
socket, install the four set screws and lock  
washers. Note the two copper spacers  
required for the center terminals. Tighten the  
screws finger tight, then to between 24 and 28  
in-lbs, then again to between 40 and 48 in-lbs.  
3. Remove the PC board.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-54  
F-54  
TROUBLESHOOTING & REPAIR  
DIODE MODULE REMOVAL AND REPLACEMENT  
FIGURE F.23 – DIODE MODULE MOUNTING DETAILS  
1
2
5.0-10 IN-LBS.  
2 TO 3  
TURNS EACH  
FINGER TIGHT  
5.0-10 IN-LBS.  
SPRING WASHER  
PLAIN WASHER  
3
4
30-40 IN.LBS.  
12-18 IN.LBS.  
Removal  
2. Apply a thin, even coat (.1 to .25mm or .004  
to .010 in) of thermal joint compound  
(Penetrax A-13) to the diode module base  
plate only, under the plastic body of the mod-  
ule. Do not apply compound to the area  
under the mounting holes.  
Refer to Figure F.23.  
1. Remove the Power Module PC Board as  
described above.  
2. Using the 7/16" wrench, remove the two  
outer screws, spring washers, and large flat  
washers from the diode module.  
3. Press the module firmly against the heat sink,  
aligning the mounting holes.  
3. Using the 9/64" allen wrench, remove the set  
screw from the center of the diode module.  
4. Place a spring washer then a flat washer over  
each outer mounting screw and insert them  
into the holes. Insert the allen head screw  
into the center hole. Tighten all three screws  
finger-tight only. ➀  
4. Remove the diode module from the heat sink.  
Replacement  
5. Using the torque wrench and 7/16" socket,  
tighten each outer screw between 5.0 and 10  
in-lbs. ➀  
Refer to Figure F.23.  
CAUTION  
6. Using the torque wrench and 9/64" allen  
head socket, tighten the center screw  
between 12 and 18 in-lbs. ➀  
The proper tightening sequence is required to  
mount the diode module to the heat sink in order  
to avoid warping the base plate. Apply the prop-  
er torque to all fasteners.  
7. Now tighten the two outer screws between 30  
and 40 in-lbs. ➀  
8. Replace the Power Module PC board as  
described above.  
1. Be sure the heat sink mounting surface is  
clean, dry, and free of grease.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-55  
F-55  
TROUBLESHOOTING & REPAIR  
POWER CAPACITOR REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-  
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
DESCRIPTION  
This procedure will aid the technician in the removal and replacement of the power capacitors.  
MATERIALS NEEDED  
3/8" Wrench or socket wrench  
7/16" Wrench  
9/16" Wrench  
Slot headed screw driver  
This procedure should take approximately 30 minutes to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-56  
F-56  
TROUBLESHOOTING & REPAIR  
POWER CAPACITOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.24 – POWER CAPACITOR MOUNTING DETAILS  
CLAMPS  
POWER  
CAPACITORS  
VERTICAL  
BAFFLE  
PROCEDURE  
1. Perform the Case Cover Removal proce-  
5. With the slot headed screw driver, loosen the  
clamps holding the capacitors to the vertical  
baffle.  
dure.  
2. Perform the Power Module Capacitor  
Discharge procedure.  
6. Slip the capacitors out of the vertical baffle.  
3. Label all leads for reassembly.  
To reassemble, slide the capacitors into the verti-  
cal baffle, observe capacitor polarity and lead ori-  
entation, and tighten the holding clamps.  
Replace the leads and straps as labeled and  
tighten the fasteners to between 50 and 60 in-lbs.  
Perform the Case Cover Replacement proce-  
dure.  
4. With the 7/16" wrench, remove the nuts, lock  
washers, and flat washers holding the leads  
and straps to the power capacitor terminals.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-57  
F-57  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE AND CHOKE  
REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-  
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing and replacing the output rectifier  
bridge and the choke from the Ranger 250.  
MATERIALS NEEDED  
5/16" Nut driver  
3/8" Wrench or socket wrench  
1/2" Wrenches (two)  
9/16" Wrench  
Diagonal cutters  
This procedure should take approximately 1 hour to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-58  
F-58  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE AND CHOKE  
REMOVAL AND REPLACEMENT (continued)  
FIGURE F.25 – OUTPUT RECTIFIER BRIDGE DETAILS  
RECTIFIER/CHOKE  
MOUNTING BRACKET  
TOP  
W1  
W2  
W3  
CENTER  
BOTTOM  
W6  
W7  
W11  
W4  
W5  
W10  
W8  
W9  
OUTPUT  
RECTIFIER  
ENGINE  
CHOKE  
CABLE  
KNOB  
BASE  
CHOKE  
FRONT  
PANEL  
REMOVAL PROCEDURE  
Refer to Figure F.25.  
4. Note the position of the engine choke cable  
for reassembly purposes. Using the 5/16" nut  
driver, remove the clamp holding the engine  
choke cable to the choke control lever at the  
carburetor. Flex the cable outward to free it  
from the lever.  
Output Rectifier  
1. Turn the engine off.  
2. Perform the Case Cover Removal procedure.  
3. Perform the Power Module Capacitor  
Discharge procedure.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-59  
F-59  
TROUBLESHOOTING & REPAIR  
OUTPUT RECTIFIER BRIDGE AND CHOKE  
REMOVAL AND REPLACEMENT (continued)  
5. Using the 1/2" and 9/16" wrenches, hold  
REPLACEMENT PROCEDURE  
and loosen the nut holding the engine  
choke cable to the back of the front panel.  
Pull the cable through the front panel. Save  
the sleeve and nut for reassembly.  
Output Choke  
1. Place the choke into the machine so that  
the three mounting holes line up with the  
mounting holes in the machine mounting  
bracket.  
6. With the 3/8" socket wrench, remove the  
four screws holding the front panel to the  
machine base. Tilt the front panel as far for-  
ward as the attached leads will permit. Cut  
any necessary cable ties.  
2. Insert the three long bolts through the choke  
and the mounting bracket. Place a lock  
washer and nut on each bolt and tighten with  
the 1/2" wrenches.  
7. With two 1/2" wrenches, remove heavy  
leads W6, W11 and W7 and their bolt, lock  
washers and flat washers from the negative  
strap on the right side of the output rectifier.  
3. Using the 1/2" wrenches, attach the heavy  
flex leads W8, W9 and W10 to the appropri-  
ate choke lead connections. See the Wiring  
Diagram.  
8. With two 1/2" wrenches, remove heavy  
leads W4 and W5 and their bolt, lock wash-  
ers and flat washers from the positive strap  
of the output rectifier.  
Output Rectifier  
1. Place the output rectifier into the machine so  
that its mounting studs fit into the holes in the  
bracket. Attach the nuts and lock washers  
using the 1/2" wrench.  
9. With two 1/2" wrenches remove heavy  
leads W1, W2, and W3 and their bolts, lock  
washers and flat washers from the three  
straps on the left side of the output rectifier.  
2. Attach heavy leads W1, W2, and W3 to the  
three straps on the left side of the rectifier  
plates. See Figure F.25 for placement.  
10. With the 1/2" wrench or socket wrench,  
remove the nuts and lock washers holding  
the output rectifier to the machine mounting  
bracket. You will need to reach through the  
large access holes on either side of the rec-  
tifier to place the wrench on these nuts.  
3. Attach heavy leads W4 and W5 to the posi-  
tive strap on the rectifier. See Figure F.25 for  
placement.  
11. Remove the output rectifier from the  
machine.  
4. Attach heavy leads W6, W11 and W7 to the  
negative strap of the rectifier. See Figure  
F.25 for placement.  
Output Choke  
5. Attach the front panel to the machine base  
with four 3/8" screws. Replace any cable ties  
cut during removal.  
1. Remove the output rectifier as described  
above.  
6. Insert the engine choke cable through the  
case front, attach it with the 9/16" nut and  
install the sleeve. Fit the end of the cable into  
the hole in the choke control lever, then  
attach the cable to the choke control lever in  
the position noted at disassembly using its  
5/16" clamp.  
2. Using the 1/2" wrenches, remove the heavy  
flex leads W8, W9 and W10 from the choke.  
3. Using the 1/2" wrenches, remove the three  
long bolts, lock washers, and nuts holding  
the choke to the mounting bracket in the  
machine base. Note that the lower right  
corner of the choke has no bolt.  
7. Perform the Case Cover Replacement pro-  
4. Carefully remove the choke.  
cedure.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-60  
F-60  
TROUBLESHOOTING & REPAIR  
ENGINE/STATOR/ROTOR REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manual.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshoot-  
ing assistance before you proceed. Call 216-383-2531 or 1-800-833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing and replacing the gasoline engine,  
stator and rotor for repair or replacement. This procedure is for Onan models only. Some pro-  
cedures may vary slightly for Kohler models.  
MATERIALS NEEDED  
5/16" Nut driver  
3/8" Deep socket  
3/8" Wrench or socket wrench  
7/16" Wrench or socket wrench  
1/2" Wrench or socket wrench  
3/4" Wrench  
Slot head screw driver  
Phillips head screw driver  
Gear puller (small)  
Hoist, chains, straps  
9/16" Wrench  
1/2" Box end wrench  
Diagonal cutters  
Feeler gauge (for air gap check)  
Machine Wiring Diagram  
Rubber or wooden mallet  
Torque wrench with 1/2" socket  
Impact wrench  
Loctite 271 thread sealant  
This procedure should take approximately 3 hours to perform.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-61  
F-61  
TROUBLESHOOTING & REPAIR  
ENGINE/STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.26 – BATTERY AND CASE BACK REMOVAL  
ACCESS PANEL  
SCREWS (3)  
REMOVAL PROCEDURE  
6. With the 1/2" wrench, loosen the bolt on the  
Engine Preparation and Lead Disconnection  
negative battery cable clamp. Remove the  
clamp and cable from the post.  
1. Turn the engine off.  
7. Using the 3/8" socket wrench, remove the  
2. Perform the Case Cover Removal proce-  
eight screws holding the case back to the  
machine base (four on each side). Remove  
3. Disconnect the spark plug wires from the  
the case back.  
dure.  
spark plugs.  
8. Using the 1/2" wrench, remove the engine  
4. Perform the Power Module Capacitor  
ground strap where it connects to the engine  
mounting foot on the left side.  
Discharge procedure.  
5. Using the 3/8" socket wrench, remove the  
9. Note the position of the choke cable for  
screws holding the battery access panel to  
reassembly purposes. Using the 5/16" nut  
the case back. Slide the panel, with the bat-  
driver, remove the clamp holding the engine  
tery attached, out of the machine far enough  
choke cable to the choke control lever. Flex  
to access the battery cables. See Figure  
the cable outward to free it from the lever.  
F.26.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-62  
F-62  
TROUBLESHOOTING & REPAIR  
ENGINE/STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F. 27 – ENGINE STARTER SOLENOID LEADS (ONAN ENGINE SHOWN)  
STARTER  
PLASTIC  
COVER ON  
SOLENOID  
10. Refer to Figure F.27. Label engine starter  
solenoid leads #211A and #209 (#211A  
attaches to the solenoid spade terminal and  
#209 attaches to the positive stud on the  
solenoid along with the positive battery  
cable). Pull lead #211A off its spade terminal.  
To remove lead #209, you will have to  
remove the plastic cover on the starter first.  
To do this, use the 1/2" socket wrench to  
remove the nut on the negative stud of the  
solenoid. Then remove the plastic cover.  
Next, remove the 1/2" nut from the positive  
solenoid stud. Now you can remove lead  
#209 and the positive battery cable from the  
starter solenoid.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-63  
F-63  
TROUBLESHOOTING & REPAIR  
ENGINE/STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.28 – STATOR LEADS (FRONT PANEL)  
RUN STOP  
SWITCH - S1  
START BUTTON SWITCH - S2  
221 (KOHLER ONLY)  
HOUR METER  
+
PCB7  
IDLER SWITCH - S4  
BATTERY  
DISPLAY  
J34  
212  
229  
5J (KOHLER ONLY)  
251  
228  
1
211  
211A  
250  
5G  
224  
5J  
210A  
210B  
210C  
224B  
230  
210  
1
210A PCB6  
THERMAL  
DISPLAY  
J33  
231  
OUTPUT CONTROL  
R1  
10K  
77 76  
75  
WELD MODE SWITCH - S6  
C1  
WELD TERMINALS  
(CONTACTOR) SWITCH - S3  
208A  
ARC CONTROL  
214  
POS. 1 CV WIRE  
POS. 2 PIPE  
222  
1
WIRE FEEDER  
VOLTMETER  
SWITCH - S5  
R2  
10K  
2
3
218  
220  
POS. 3 CC STICK  
POS. 4 TOUCH START TIG  
4
21  
206A  
GND M  
GND L  
4
GND J  
GND G  
2A  
4A  
2
277 276  
275  
GND D  
GND C  
GND B  
GND A  
20 AMP  
50 AMP  
3
3A  
25 AMP  
209  
3D  
GND C  
3A  
AMPHENOL 1  
AMPHENOL 2  
C
GOLD  
J102  
31  
5
5A  
5B  
5C  
CB7  
CB1  
CB5  
3E  
C
B
A
212A  
212  
J100  
3E  
3D, 32  
B
D
D
SILVER  
5A  
L
6F  
K
J
120/240 V AC  
GND G  
E
A
M
5F  
5G  
5H  
5K  
E
N
I
6
6B  
CB6  
6B  
42  
F
F
6E  
G
H
CB2  
CB8  
GND E  
GOLD  
5L  
KEY  
5C  
6F  
42A  
J101  
6E  
KEY  
SILVER  
5B  
50 AMP  
15 AMP  
20 AMP  
GND D  
208  
SHUNT  
208A  
208B  
206A  
206B  
POSITIVE OUTPUT STUD  
NEGATIVE OUTPUT STUD  
204S 206S  
CASE FRONT - REAR VIEW  
Stator Lead Disconnection  
5. Remove lead #42 from circuit breaker CB8.  
Refer to Figure F.28.  
6. Remove stator auxiliary winding lead #6 from  
circuit breaker CB6 and lead #3 from circuit  
breaker CB5. These leads pass through the  
toroid. For reassembly, note the number of  
turns and direction through the toroid for  
each lead. See the Wiring Diagram.  
NOTE: Use diagonal cutters to cut any cable ties  
necessary to free the leads as described below.  
1. With two 1/2" wrenches remove heavy flex  
leads W1, W2, and W3 and their bolts, lock  
washers and flat washers from the straps on  
the left side of the output rectifier plates. See  
Figure F.25.  
7. Separate and remove lead #5H, #201, #200A  
and #200 at their piggy-back connections at  
the brush holder. See the Wiring Diagram.  
2. Remove field winding leads #7 and #9 from  
8. Disconnect plug J51 (Engine Connector  
Block).  
the field rectifier bridge. See Figure F.9.  
3. Disconnect lead #41 from its in-line coupling.  
9. Using the 1/2" wrench, disconnect the engine  
ground lead (GND J) at the engine foot. This  
is the small lead that runs to the top ground  
stud on the case front.  
4. Using a 3/8" deep socket or wrench, remove  
leads #5 and GND E from the bottom ground  
stud on the case front. See the Wiring  
Diagram.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-64  
F-64  
TROUBLESHOOTING & REPAIR  
ENGINE/STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.29 – ENGINE/STATOR/ROTOR ASSEMBLY REMOVAL  
LIFTING  
EYE (2)  
ENGINE  
MOUNTING  
FIREWALLS  
STATOR  
SUPPORT  
BRACKET  
FUEL LINE  
Engine/Stator/Rotor Assembly  
Removal Procedure  
3. Remove the fuel line at the carburetor and  
plug it.  
Refer to Figure F.29.  
4. Using the hoist, you can now lift the  
engine/stator assembly free from the  
machine base. Note that the firewall baffle  
assembly surrounding the muffler (Onan  
engine machines) and stator come with the  
1. Attach chains to the lifting eyes on the top  
sides of the engine and the stator lift bail.  
Secure the chains to the hoist and put  
enough tension on them to support the  
engine but without lifting the assembly.  
engine/stator/rotor assembly.  
secured to the machine base.  
It is not  
2. Using the 9/16" wrench, remove the two  
bolts, lock washers, and nuts from the stator  
bottom support bracket and two bolts, wash-  
ers and nuts from the engine mountings.  
5. Set the assembly carefully on a workbench or  
the floor. Place a wooden block under the  
stator before removing support from the  
hoist.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-65  
F-65  
TROUBLESHOOTING & REPAIR  
ENGINE/STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.30 – STATOR AND ROTOR REMOVAL  
1. STATOR  
2. BRUSH HOLDER ASSEMBLY  
3. ROTOR THRU-BOLT  
4. BLOWER FAN  
5. TOLERANCE RING  
6. ROTOR BEARING  
7. IDLER SOLENOID  
8. ROTOR  
9. LIFTING EYE  
9
8
2
1
6
5
3
4
7
Stator/Rotor Assembly Removal  
Refer to Figure F.30.  
4. Using the 7/16" wrench, remove the two nuts,  
lock washers, and bolts holding the brush  
holder assembly to the stator frame.  
Remove the brush holder assembly.  
1. Support the stator with the hoist.  
2. Using the 1/2" wrench, remove the bolt,  
washers, and nut holding the muffler to the  
stator (Onan engine machines). Remove the  
bolts and washers holding the muffler to the  
engine and remove the muffler.  
5. Unscrew the fan to remove it from the shaft.  
Turn the fan counterclockwise. Be careful not  
to lose the washer that fits between the blow-  
er fan and the rotor.  
3. Disconnect the idler solenoid linkage at its  
clip.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-66  
F-66  
TROUBLESHOOTING & REPAIR  
ENGINE/STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
6. Double check that the spark plug wires  
are disconnected. You will be turning the  
rotor during this procedure, and this could  
cause engine kickback.  
15. Carefully remove the rotor from the stator.  
You can tap carefully on the end of the rotor  
shaft with a rubber mallet. Guide the rotor  
carefully to prevent damage to its core.  
7. Hold the rotor shaft with locking pliers. With  
the 5/8" wrench or an impact wrench,  
remove the rotor thru-bolt. Hold the rotor  
with one hand and shock the wrench with a  
mallet to loosen the thru-bolt. The thru-bolt  
has a centering washer, tapered to conform  
to the rotor shaft.  
REASSEMBLY NOTES  
Reassemble the rotor and stator to the Ranger  
250 by carefully retracing the disassembly proce-  
dure steps in reverse order. Keep the following  
special points in mind as you proceed. A Lead  
Reconnection Checklist is provided here to aid in  
reassembly.  
8. Remove the thru-bolt and washer from the  
end of the rotor.  
Rotor/Stator/Engine Reassembly  
9. Install the appropriate long thru-bolt (two  
are provided) supplied with Lincoln Electric  
Rotor Puller Kit S20788. The slot head  
must face out. Screw in the bolt with the  
slot head screw driver until the bolt bottoms  
out on the engine crankshaft, about 3/4".  
Refer to Figure F.30.  
NOTE: Lincoln Electric recommends that you  
install a new bearing (Lincoln part #M9300-85)  
and tolerance ring (Lincoln part #S18044-9) any  
time the stator and rotor are reassembled.  
10. Turning it counterclockwise, screw in the  
left-hand thread rotor removal tool from the  
kit into the rotor shaft. Carefully prevent the  
rotor from turning - use locking pliers.  
Tighten the tool to approximately 50 ft lbs  
with the torque or impact wrench. The rotor  
should "pop" off the engine crankshaft.  
1. Fit the rotor into the stator, being careful not  
to damage the rotor core against the stator.  
Position the rotor so that the laminations are  
at top and bottom and air gap at the sides.  
This will limit movement of the rotor.  
IMPROPER HANDLING OF THE ROTOR  
CAN RESULT IN SHORTED WINDINGS  
AND/OR LOST OUTPUT.  
11. If the rotor does not pop off, continue to  
carefully prevent the rotor shaft from turning  
and tighten the rotor removal tool an addi-  
tional 5 ft lbs. until the rotor pops off the  
engine crankshaft.  
2. Tap the rotor carefully with a mallet to fit the  
bearing all the way into the stator frame.  
3. Clean the tapered engine crankshaft.  
12. With the 7/16" wrench, remove the side fire-  
walls.  
4. Using the hoist, carefully fit the stator/rotor  
assembly onto the engine crankshaft.  
13. With the 9/16" wrench, remove the four  
bolts that hold the stator to the engine.  
There is one lock washer per bolt.  
5. Install the four bolts that mount the stator to  
the engine. NOTE: Apply Loctite 271 thread  
sealant to the two bottom bolts on the  
ONAN engine, to prevent oil leakage from  
the crankcase. With the 9/16" wrench, draw  
the bolts up evenly in order to seat the rotor  
bearing properly. Tighten moving diagonal-  
ly from bolt to bolt.  
14. Carefully remove the stator/rotor assembly  
from the engine. Once the assembly is sep-  
arated from the engine, be careful that the  
rotor does not fall out of the stator.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-67  
F-67  
TROUBLESHOOTING & REPAIR  
ENGINE/STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
6. Insert the rotor thru-bolt and centering wash-  
LEAD RECONNECTION CHECKLIST  
er. With the torque wrench and socket, tight-  
en the bolt to 50 ft lbs. Then recheck all four  
engine-stator mounting bolts for tightness.  
Engine  
➀ Plug J51  
7. Check the rotor-stator air gap with a .017  
feeler gauge. The measurement is taken at  
the blower end of the rotor before the fan is  
➀ Brush leads #201(-) and 5H (-) and #200A(+)  
and #200 (+) at their proper brush holder  
reinstalled. (The rotor has two flat sides,  
connections  
which are not measured for air gap.) Slide in  
the gauge. Then rotate the shaft 180  
Stator  
degrees and measure again. If the gauge  
does not clear, loosen the rotor thru-bolt and  
four engine-stator bolts; retighten the bolts  
and recheck the air gap. Repeat until the  
proper .017 minimum air gap is achieved.  
➀ Heavy leads #W1, W2, and W3 to the output  
rectifier bridge  
➀ Field winding leads #7 and #9 to the field rec-  
tifier bridge  
8. Screw the blower fan back onto the end of  
the rotor shaft. Be sure the washer is in  
place and hand-tighten the fan only.  
➀ Lead #41 to #41A at their in-line coupling  
Front Panel  
9. Install the muffler to the engine. Use new  
gaskets if necessary. Position the vertical  
firewall as you install the muffler. Then  
install the 1/2" bolt, washers, and nut that  
hold the muffler to the stator frame.  
➀ Small green engine ground lead to the top  
ground stud on the case front panel (GND J)  
➀ Lead #5 and GND E to bottom ground stud  
10. Install the side firewalls.  
➀ Lead #6 to circuit breaker CB6 and lead #3 to  
circuit breaker CB5 through the toroid (Note  
number of turns and direction. See the  
Wiring Diagram.)  
11. Reassemble the idler solenoid linkage.  
12. Connect the engine ground strap to the  
engine mounting foot.  
➀ Lead #42 to circuit breaker CB8  
13. Attach the stator to its bottom support  
bracket and reinstall the engine mounting  
hardware.  
GENERAL NOTES ON REASSEMBLY  
1. Replace any cable ties cut during disassem-  
bly.  
14. Connect the engine starter solenoid leads.  
15. Connect the engine choke cable and fuel  
line.  
2. When installing the battery, connect the pos-  
itive battery cable, then the negative battery  
cable. BE SURE TO CONNECT THE POSI-  
TIVE BATTERY CABLE FIRST.  
16. Install the brush holder assembly and leads.  
17. Install the case back.  
3. Connect the spark plug wires.  
18. Install the battery. Connect the positive bat-  
tery cable first, then the negative battery  
cable. BE SURE TO CONNECT THE POS-  
ITIVE BATTERY CABLE FIRST.  
4. Perform the Case Cover Replacement pro-  
cedure.  
5. Conduct the Retest after Repair procedure,  
the following topic in this section of the man-  
ual.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-68  
F-68  
TROUBLESHOOTING & REPAIR  
RETEST AFTER REPAIR  
Retest a machine:  
• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the  
machine’s electrical characteristics. OR  
• If you repair or replace any electrical components.  
ENGINE OUTPUT  
Mode  
Low Idle  
High Idle  
No Load RPM  
2350 - 2450  
3700 - 3750  
Load RPM  
N/A  
3350 - 3580  
WELDER DC (STICK) OUTPUT (ARC control @ -10)  
Mode Selector  
Output Control  
Open Circuit  
Volts  
Load Volts  
Load Amps  
Switch  
Stick (CC)  
Maximum  
74-79  
25-30  
245-265  
WELDER CV (WIRE) OUTPUT (ARC Control @ +10)  
Mode Selector  
Output Control  
Open Circuit  
Voltage  
56-64  
Load Volts  
Load Amps  
Switch  
CV  
CV  
Maximum  
Minimum  
25-30  
13-14.5  
245-265  
25-30  
20-28  
TOUCH START TIG (ARC Control @ +10)  
Mode Selector  
Switch  
TIG  
Output Control  
Open Circuit  
Voltage  
16-19  
Load Volts  
Load Amps  
Maximum  
Minimum  
25-30  
Short Circuit  
245-265  
19-24  
TIG  
16-19  
AUXILIARY POWER OUTPUT  
240 Volt Receptacle  
120 Volt Receptacles  
Open Circuit  
Voltage  
Load Volts  
Load Amps  
Open Circuit  
Voltage  
Load Volts  
Load Amps  
236-252  
216-225  
35-39  
118-126  
110-120  
18-22  
42 VOLT WIRE FEEDER POWER  
Open Circuit Voltage  
Load Volts  
Load Amps  
7.0-9.0  
42-46  
40-44  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-1  
G-1  
ELECTRICAL DIAGRAMS  
TABLE OF CONTENTS  
-ELECTRICAL DIAGRAMS SECTION-  
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION G  
WIRING DIAGRAM RANGER 250 KOHLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2  
WIRING DIAGRAM RANGER 250 ONAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3  
CONTROL INTER-CONNECTION DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-4  
COMPLETE MACHINE SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5  
ANALOG CONTROL POWER SUPPLY PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . G-6  
BATTERY PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7  
BYPASS PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-8  
CHOPPER PC BOARD SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-9  
DISPLAY PC BOARD SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-10  
WELD CONTROL PC BOARD SCHEMATIC - SHEET 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-11  
WELD CONTROL PC BOARD SCHEMATIC - SHEET 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-12  
WELD CONTROL PC BOARD SCHEMATIC - SHEET 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-13  
WELD CONTROL PC BOARD SCHEMATIC - SHEET 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-14  
WELD CONTROL PC BOARD SCHEMATIC - SHEET 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-15  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
G-2  
G-2  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - RANGER 250 KOHLER  
RANGER 250 KOHLER - WIRING DIAGRAM  
S6 MODE SELECTOR SWITCH  
CV  
1
214  
218  
PIPE  
2
C1  
(LOCATED BELOW  
TERMINAL 1)  
J1  
Programing  
CC  
3
R1 OUTPUT CONT. POT  
4
220  
222  
TIG  
CCW  
R2 ARC CONTROL  
CCW  
10K  
W4  
D1 - THREE PHASE BRIDGE RECTIFIER  
STATOR  
WELD  
J50  
10K  
W5  
77  
HEATSINK  
D4  
75  
76  
+
279  
277  
B1  
3
6
9
2
1
4
7
WINDINGS  
222  
220  
218  
W3  
W9  
POS  
B2  
B3  
B7  
278  
5
8
+
C1  
P1-J2  
Mode  
Selection  
W1  
PC BOARD TO  
HEAT SINK CONN.  
W11  
W6  
TWISTED PAIR  
233  
TS1  
232  
214  
206S  
204S  
NEG  
NEG  
L1 CHOKE  
6
3
D2 DIODE  
MODULE  
W10  
WRAP TWO TURNS #3 &  
#6 LEADS IN DIRECTION  
11  
SHUNT  
14  
252  
P3  
JUMPER  
PLUG  
J3  
Machine  
Selection  
PC BOARD TO  
HEAT SINK CONN.  
50MV=400 AMPS  
P50  
SHOWN THROUGH  
1
2
5
8
3
6
9
W6  
12  
TOROID  
4
7
206B  
206A  
R3  
C2  
+
CONTACTOR  
CONTROL  
6
3
W8  
+
W11  
300 AMP  
MODULE  
W2  
23  
PCB 1  
253  
4A  
W3  
25  
208B  
2A  
4
S3  
2
261  
260  
13  
J4  
260A  
261A  
SHOWN IN  
Meter  
"WELDING ON"  
POSITION  
TWISTED PAIR  
W7  
208  
14  
13  
P41-J41  
P42-J42  
IDLER CONTROL  
S5  
FIELD WINDING  
42 VAC  
208A  
STATOR AUX. WINDING  
6
VOLTMETER  
POLARITY  
SWITCH  
J5  
WIRE FEED POWER  
WINDING  
206A  
3
251  
S4  
Meter  
250  
118A  
7
9
115A  
116A  
5
GND-E  
L3  
42 VAC  
SHOWN IN  
5L  
206S  
204S  
"AUTO" POSITION  
P6-J6  
Shunt  
21  
42  
41  
SHOWN IN  
POSITIVE (+)  
POSITION  
101A  
12  
105A  
11  
76  
77  
75  
P7-J7  
Output  
Control  
PCB2 ANALOG POWER PC BOARD  
6
CB8  
3
J8  
Hot Start  
15A  
41A  
42A  
5L  
278  
277  
279  
GND-K  
BOTTOM GND. SCREW ON  
INSIDE OF CASE FRONT  
P9-J9  
Pinch/  
Arc Force  
4
8
200B  
J
31  
32  
208  
5H  
L2  
115AC  
GND-L  
GND. SCREW ON  
GND E  
GND M  
P60  
J60  
206B  
9
A
D
C
H
E
F
G
I
5G  
5K  
75A  
4B  
CONTACTOR  
WORK  
5F  
CENTER BAFFLE  
2B  
21  
1
3
209  
76A 2  
P10-J10  
14 Pin  
Ampenol  
GND-K  
5
CENTER GND. SCREW ON  
INSIDE OF CASE FRONT  
5
6
77A4  
D3  
25A  
CB7  
7
77B  
76B  
75B  
41A  
42A  
3
C3  
REMOTE  
31  
800uf  
150vdc  
TOP GND. SCREW ON  
INSIDE OF CASE FRONT  
CONTROL  
2C  
2B  
2A  
WHITE  
5C  
212A  
4C  
4B  
4A  
P61  
J61  
201A  
230  
42VAC  
GROUND  
K
B
5A  
FRAME GND.  
232  
212  
IDLE SOLENOID  
P11-J11  
Thermal  
200  
200A  
6
GND-A  
4
S1RUN-STOP  
SWITCH  
233  
1
6
GND-A  
GND-J  
5B  
231  
AMPHENOL 1  
(SHOWN IN  
RUN POS.)  
210C  
210C  
12  
32  
208B  
250  
251  
77B  
77A  
76A  
75B  
75A  
77C  
76C  
75C  
2C  
4C  
GND-B  
201  
A
FRAME GND.  
WHITE  
S1  
S2  
77C  
GND-G  
REMOTE  
B
20A  
START  
5H  
221  
BUTTON  
GND-B  
CONTROL  
C
BLACK  
3D  
P62  
J62  
J102  
215  
215  
76C  
76B  
75C  
3A  
211  
D
POS.BRUSH  
210D  
23  
NEG. BRUSH  
CB1  
CONTACTOR  
E
P12-J12  
211A  
GROUND  
F
GND-D  
SILVER  
20A  
5A  
Sense/  
Idler/  
PWM  
5J  
1
7
3A  
5C  
BLACK  
6E  
260A  
261A  
AMPHENOL 2  
210B  
LEAD COLOR CODE:  
B=BLACK OR GRAY  
R=RED OR PINK  
W=WHITE  
CND-C  
6B  
210A  
ROTOR  
BYPASS  
PC BOARD  
CB2  
25  
J101  
210  
224B HOUR METER  
3
POSITIVE BRUSH CONNECTED  
TO SLIP RING NEAREST  
TO THE LAMINATION  
+
116A  
224  
SILVER  
5F  
5B  
G=GREEN (W/YELLOW STRIPE)  
105A  
101A  
118A  
5J  
CB535A  
P13-J13  
POWER  
1
2
1
4
3
6
3A  
BLACK  
6B  
3
3E  
115A  
1
5
4
8
1
2
1
5
J100  
115/230V  
35A  
5G  
211A  
225  
209  
3E  
CB6  
BLACK  
WHITE  
6
6F  
PCB3 WELD CONTROL PC BOARD  
3
4
229  
6
10  
6B  
212A  
+
1
WHITE  
TERM.  
5C  
1
9
6
8
12 VOLT  
221  
L2, L3: RF CHOKES  
BATTERY  
P51  
228  
PCB7 Battery Display  
ENGINE TERMINAL  
BLOCK  
-
P34-J34  
1
2
3
R
4
R
12  
16  
7
J51  
U
224  
ELECTRICAL SYMBOLS PER E1537  
CONNECTORS VIEWED FROM INSERTION END  
ENGINE  
GROUND  
WHITE  
V
GROUNDING THIS CIRCUIT  
STOPS THE ENGINE  
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.  
GND-H  
STARTER  
FRAME  
GROUND  
210  
224B  
228  
REGULATOR  
CR1  
STARTER  
SOLENOID  
OIL  
PRESSURE  
SWITCH  
AC  
AC  
B
+
B-  
231  
210B  
229  
PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE  
(VIEWED FROM LEAD SIDE OF RECEPTACLE)  
IGNITION  
MODULE  
210D  
200  
FUEL  
SHUTOFF  
SOLENOID  
P43-J43  
GND J  
FLYWHEEL ALTERNATOR  
211  
KOHLER ENGINE COMPONENTS  
3
6
9
2
5
8
1
4
7
230  
PCB6 Thermal Display  
5K  
1 2 3  
4 5 6  
7 8 9  
P33-J33  
225  
PCB4 BATTERY PC BOARD  
9 PIN  
J50  
9 PIN  
P50  
4-14-2000  
G3667  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
G-3  
G-3  
ELECTRICAL DIAGRAMS  
WIRING DIAGRAM - RANGER 250 ONAN  
RANGER 250 ONAN - WIRING DIAGRAM  
S6 MODE SELECTOR SWITCH  
CV  
1
214  
218  
PIPE  
2
C1  
(LOCATED BELOW  
TERMINAL 1)  
J1  
Programing  
CC  
3
R1 OUTPUT CONT. POT  
4
220  
222  
TIG  
CCW  
R2 ARC CONTROL  
10K  
W4  
D1 - THREE PHASE BRIDGE RECTIFIER  
CCW  
STATOR  
WELD  
J50  
10K  
W5  
77  
HEATSINK  
D4  
75  
76  
+
279  
277  
B1  
3
6
9
2
1
4
7
WINDINGS  
W3  
222  
220  
218  
W9  
POS  
B2  
278  
5
8
+
C1  
B3  
B7  
P2-J2  
Mode  
Selection  
W1  
PC BOARD TO  
HEAT SINK CONN.  
W11  
W6  
TWISTED PAIR  
233  
TS1  
232  
214  
206S  
204S  
NEG  
NEG  
L1 CHOKE  
6
D2 DIODE  
MODULE  
W10  
WRAP TWO TURNS #3 &  
#6 LEADS IN DIRECTION  
11  
SHUNT  
14  
252  
P3  
JUMPER  
PLUG  
J3  
Machine  
Selection  
PC BOARD TO  
HEAT SINK CONN.  
50MV=400 AMPS  
P50  
3
SHOWN THROUGH  
1
2
5
8
3
6
9
W6  
12  
TOROID  
4
7
206B  
206A  
R3  
C2  
+
CONTACTOR  
CONTROL  
6
3
W8  
+
W11  
300 AMP  
MODULE  
W2  
23  
PCB 1  
253  
4A  
W3  
25  
208B  
2A  
4
S3  
2
261  
260  
13  
J4  
260A  
261A  
SHOWN IN  
Meter  
"WELDING ON"  
POSITION  
TWISTED PAIR  
W7  
208  
14  
P41-J41  
IDLER CONTROL  
13  
S5  
FIELD WINDING  
42 VAC  
208A  
STATOR AUX. WINDING  
6
VOLTMETER  
POLARITY  
SWITCH  
J5  
WIRE FEED POWER  
WINDING  
206A  
3
251  
S4  
Meter  
250  
118A  
115A  
116A  
5L  
7
9
5 GND-E  
L3  
42 VAC  
SHOWN IN  
206S  
204S  
"AUTO" POSITION  
P6-J6  
Shunt  
21  
42  
P42-J42  
41  
SHOWN IN  
POSITIVE (+)  
POSITION  
101A  
105A  
12  
11  
76  
77  
75  
P7-J7  
Output  
Control  
PCB2 ANALOG POWER PC BOARD  
6
CB8  
3
J8  
Hot Start  
15A  
41A  
42A  
5L  
278  
277  
279  
GND-K  
P9-J9  
Pinch/  
Arc Force  
BOTTOM GND. SCREW ON  
INSIDE OF CASE FRONT  
4
8
200B  
J
31  
32  
208  
5H  
GND-E  
GND-M  
L2  
GND-L  
115AC  
P60  
J60  
206B  
9
A
D
C
H
E
F
5G  
5K  
GND. SCREW ON  
CENTER BAFFLE  
75A  
4B  
CONTACTOR  
WORK  
5F  
1
3
2B  
21  
209  
76A 2  
P10-J10  
14 Pin  
Ampenol  
GND-K  
5
CENTER GND. SCREW ON  
5
6
77A4  
INSIDE OF CASE FRONT  
D3  
25A  
CB7  
7
77B  
76B  
75B  
41A  
42A  
3
C3  
REMOTE  
31  
800uf  
150vdc  
TOP GND. SCREW ON  
INSIDE OF CASE FRONT  
CONTROL  
2C  
2B  
2A  
G
I
K
B
WHITE  
5C  
212A  
4C  
4B  
4A  
P61  
J61  
201A  
230  
42VAC  
GROUND  
5A  
FRAME GND.  
232  
212  
IDLE SOLENOID  
P11-J11  
Thermal  
200  
200A  
6
GND-A  
4
S1RUN-STOP  
SWITCH  
233  
1
6
GND-A  
GND-J  
5B  
231  
AMPHENOL 1  
(SHOWN IN  
RUN POS.)  
210C  
210C  
32  
12  
208B  
77B  
77A  
76A  
75B  
75A  
77C  
76C  
75C  
2C  
4C  
GND-B  
201  
A
FRAME GND.  
GND-B  
WHITE  
S1  
S2  
77C  
GND-G  
REMOTE  
B
250  
20A  
START  
5H  
BUTTON  
251  
25  
CONTROL  
C
P62  
J62  
BLACK  
3D  
J102  
215  
215  
76C  
76B  
75C  
3A  
211  
D
POS.BRUSH  
210D  
23  
NEG. BRUSH  
CB1  
CONTACTOR  
E
P12-J12  
211A  
GROUND  
GND-D  
F
SILVER  
20A  
5A  
Sense/  
Idler/  
PWM  
1
7
3A  
5C  
BLACK  
6E  
260A  
261A  
LEAD COLOR CODE:  
B=BLACK OR GRAY  
R=RED OR PINK  
W=WHITE  
AMPHENOL 2  
210B  
CND-C  
6B  
210A  
ROTOR  
BYPASS  
PC BOARD  
CB2  
J101  
224B  
3
POSITIVE BRUSH CONNECTED  
TO SLIP RING NEAREST  
TO THE LAMINATION  
212 A  
+
210  
116A  
G=GREEN (W/YELLOW STRIPE)  
SILVER  
5F  
5B  
105A  
101A  
118A  
CB535A  
3A  
HOUR METER  
P13-J13  
POWER  
5G  
1
2
1
4
3
6
209  
1
5
4
8
1
1
5
BLACK  
6B  
3
3E  
115A  
J100  
115/230V  
35A  
3E  
12 VOLT  
BATTERY  
+
2
CB6  
3
4
10  
BLACK  
WHITE  
6
6
6F  
PCB3 WELD CONTROL PC BOARD  
229  
6B  
1
1
9
6
8
P51  
J51  
WHITE  
TERM.  
5C  
L2, L3: RF CHOKES  
FRAME  
GROUND  
1
2
3
4
228  
PCB7 Battery Display  
12  
16  
7
P34-J34  
GND-H  
CR1  
STARTER  
SOLENOID  
TO  
SPARK  
PLUGS  
ENGINE  
TERMINAL BLOCK  
GND-J  
ELECTRICAL SYMBOLS PER E1537  
CONNECTORS VIEWED FROM INSERTION END  
ENGINE  
STARTER  
GROUND  
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.  
OIL  
PRESSURE  
SWITCH  
REGULATOR  
AC  
224B  
228  
AC B+  
B-  
231  
210B  
229  
IGNITION  
CONTROL  
PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE  
(VIEWED FROM LEAD SIDE OF RECEPTACLE)  
210D  
200  
P43-J43  
FLYWHEEL ALTERNATOR  
211  
CAPACITOR  
3
6
9
2
5
8
1
4
7
230  
PCB6 Thermal Display  
5K  
ONAN ENGINE COMPONENTS  
1 2 3  
4 5 6  
7 8 9  
P33-J33  
PCB4 BATTERY PC BOARD  
9 PIN  
J50  
9 PIN  
J50  
4-14-2000  
G3675  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
G-4  
G-4  
ELECTRICAL DIAGRAMS  
CONTROL INTER-CONNECTION DIAGRAM  
RANGER 250 CONTROL INTER-CONNECTION DIAGRAM  
25 1J12 to PIN 7 of P50 CHOPPER PWM SIGNAL  
CHOPPER  
23 2J12 to PIN 9 of P50 CHOPPER PWM SIGNAL  
PWM SIGNAL - TWISTED PAIR  
212 1J43 to ENGINE CONNECTOR BLOCK  
211 2J43 to S2 START SWITCH  
ENERGIZES KOHLER FUEL SOLENOID  
ENERGIZES FUEL SOLENOID WHEN STARTING ENGINE  
251 7J12 to S4 IDLER CONTROL SWITCH  
250 8J12 to S4 IDLER CONTROL SWITCH  
261A 9J12 to CURRENT SENSING TOROID  
260A 10J12 to CURRENT SENSINGTOROID  
210D 14J12 to 12J43  
215 15J12 to IDLE SOLENOID  
208B 16J12 to NEG. OUTPUT STUD  
IDLER CONTROL  
229 4J43 to 2J34 BATTERY DISPLAY PC BOARD  
TO BATTERY CHARGER TROUBLE LIGHT  
210B 5J43 to S2 START SWITCH  
AC POWER SENSE FOR IDLER  
14V SUPPLY VOLTAGE FROM BATTERY  
228 6J43 to 1J34 BATTERY DISPLAY PC BOARD  
TO BATTERY CHARGER TROUBLE LIGHT  
224B 7J43 to HOUR METER  
IDLER CLAMPING DIODE CIRCUIT  
OUTPUT TO IDLER SOLENOID, PULLSTO LOW IDLE  
ARC VOLTAGE FEEDBACK  
BATTERY VOLTAGE FROM OIL PRESSURE SWITCH FOR FLASHING CIRCUIT  
GROUND TO FRAME  
ROTOR FLASHING  
IDLER CLAMPING DIODE CIRCUIT  
5K 9J43 to GROUND SCREW  
200 11J43 to POSITIVE BRUSH HOLDER  
201D 1J43 to 14J12  
277 1J9 to R2 ARC CONTROL - 10K  
278 2J9 to R2 ARC CONTROL - 10K  
279 3J9 to R2 ARC CONTROL - 10K  
ARC  
CONTROL  
P3 JUMPER PLUG, PINS 1 AND 5  
ARE JUMPERED TOGETHER  
1
1
1
7
3
9
204S 1J6 to SHUNT POS. - W10 SIDE  
206S 2J6 to SHUNT NEG. - OUTPUT STUD SIDE  
PCB4  
BATTERY  
PC BOARD  
J6  
J4  
CURRENT LEVEL  
FEEDBACK - TWISTED PAIR  
J1  
J3  
1
RUN STOP  
SWITCH - S1  
J8  
J9  
1
START BUTTON SWITCH - S2  
221 (KOHLER ONLY)  
HOUR METER  
+
1
1
PCB7  
IDLER SWITCH - S4  
BATTERY  
DISPLAY  
J34  
PCB3  
WELD CONTROL  
PC BOARD  
J50 - CONNECTSTO  
PCB1 300 AMP  
CHOPPER MODULE  
J43  
1
212  
229  
5J (KOHLER ONLY)  
1
251  
231 1J11 to 2J33 THERMAL DISPLAY INDICATOR  
228  
J11  
J2  
1
THERMAL  
PROTECTION  
233 4J11 to THERMOSTAT ON HEAT SINK  
232 5J11 to THERMOSTAT ON HEAT SINK  
230 6J11 to 1J33 THERMAL DISPLAY INDICATOR  
J12  
211  
211A  
250  
1
1
5G  
224  
5J  
210A  
210B  
210C  
224B  
230  
210  
1
210A PCB6  
214 1J2 to MODE SWITCH - TERM.1 CV  
1
THERMAL  
DISPLAY  
218 6J2 to MODE SWITCH - TERM. 2 PIPE  
220 7J2 to MODE SWITCH - TERM. 4 TIG  
222 8J2 to MODE SWITCH - CENTER C1  
J33  
MODE  
SELECTION  
231  
OUTPUT CONTROL  
J5  
C1  
R1  
10K  
1
77A 1J10 to 5J62 - 10K REMOTE  
76A 2J10 to 4J62 - 10K REMOTE  
75A 3J10 to 2J62 - 10K REMOTE  
4 4J10 to WELDTERM. SWITCH  
2 5J10 to WELDTERM. SWITCH  
J13  
J10  
J7  
1
77 1J7 to R1 OUTPUT CONTROL  
76 2J7 to R1 OUTPUT CONTROL OUTPUT  
75 3J6 to R1 OUTPUT CONTROL CONTROL  
REMOTE INPUTS  
1
C2  
77 76  
75  
WELD MODE SWITCH - S6  
C1  
115A 1J13 to 5J42 -15 VOLT POWER  
101A 2J13 to 7J42 CIRCUIT GROUND  
105A 3J13 to 2J42 - 5 VOLT POWER  
116A 4J13 to 9J42 - 5 VOLT POWER  
118A 5J13 to 10J42 +15 VOLTS MEA.TO CASE GND.  
5F 7J13 to CASE FRONT GND. SCREW CASE GND.  
WELD TERMINALS  
(CONTACTOR) SWITCH - S3  
208A  
ARC CONTROL  
214  
POWER INPUTS  
FROM ANALOG POWER PC BOARD  
222  
POS. 1 CV-WIRE  
POS. 2 PIPE  
1
WIRE FEEDER  
VOLTMETER  
SWITCH - S5  
2
R2  
10K  
3
218  
220  
PCB5  
4
POS. 3 CC-STICK  
POS. 4 TOUCH START TIG  
BY-PASS  
PC BOARD  
PCB2  
ANALOG POWER  
PC BOARD  
1
J41  
13 1J41 to POSTERMINAL ON C2 - 85V SUPPLY  
14 2J41 to NEGTERMINAL ON C2 - 85V SUPPLY  
21  
206A  
CONTROL CIRCUIT  
INPUT POWER  
GND M  
GND L  
GND J  
GND G  
GND D  
206B 3J60 to POS. OUTPUT STUD  
GND-K 5J60 to GND. SCREW  
208 8J60 to NEG. OUTPUT STUD  
TRANSIENT PROTECTION  
AND HIGH FREQ BYPASS  
ON OUTPUT TERMINALS  
4
J60  
1
2A  
4A  
2
277 276  
275  
GND C  
GND B  
50 AMP  
20 AMP  
25 AMP  
209  
GND A  
2A 1J61 to WELDTERM. SWITCH  
3
3A  
3D  
GOLD  
3A  
AMPHENOL 1  
C
AMPHENOL 2  
GND C  
J61  
1
2B 2J61 to 14 PIN AMPHENOL PIN C  
2C 3J61 to 6 PIN AMPHENOL PIN D  
4A 4J61 to WELDTERM. SWITCH  
4B 5J61 to 14 PIN AMPHENOL PIN D  
4C 6J61 to 6 PIN AMPHENOL PIN E  
REMOTE  
CONTACTOR  
CONTROL  
31  
5
5A  
5B  
5C  
CB1  
CB5  
3E  
CB7  
212A  
212  
1
J102  
B
A
K
C
B
J100  
3E  
D
3D, 32  
D
SILVER  
5A  
L
J42  
6F  
J
J62  
1
120/240 V AC  
E
GND G  
A
M
E
N
5F  
5G  
I
6
6B  
CB6  
6B  
42  
F
F
G
6E  
GOLD  
H
5H  
5K  
5L  
CB2  
GND E  
CB8  
42A  
KEY  
75A 2J62 to 3J10 - 10K REMOTE  
75B 3J62 to 14 PIN AMPHENOL PIN G  
76A 4J62 to 2J10 - 10K REMOTE  
77A 5J62 to 1J10 - 10K REMOTE  
77B 6J62 to 14 PIN AMPHENOL PIN E  
75C 8J62 to 6 PIN AMPHENOL PIN C  
76B 9J62 to 14 PIN AMPHENOL PIN F  
76C 10J62 to 6 PIN AMPHENOL PIN B  
77C 12J62 to 6 PIN AMPHENOL PIN A  
5C  
6F  
KEY  
J101  
6E  
SILVER  
5B  
50 AMP  
20 AMP  
15 AMP  
GND K  
GND L  
REMOTE  
OUTPUT CONTROL  
GND D  
208  
SHUNT  
11 1J42 toPIN 3 of P50  
105A 2J42 to3J13  
5L 4J42 to GND. SCREW  
115A 5J42 to 1J13  
12 6J42 to PIN 1 of P50  
101A 7J42 to 2J13  
116A 9J42 to 4J13  
CHOPPER POWER SUPPLY, 20V  
WELD BOARD POWER SUPPLY, +5V TO CIRCUIT GROUND  
FRAME GROUND  
WELD BOARD POWER SUPPLY, +15VTO CIRCUIT GROUND  
CHOPPER POWER SUPPLY, 20V  
CIRCUIT GROUND  
WELD BOARD POWER SUPPLY, -15V TO CIRCUIT GROUND  
WELD BOARD POWER SUPPLY, +15V TO CASE GROUND  
208A  
208B  
206A  
206B  
POSITIVE OUTPUT STID  
NEGATIVE OUTPUT STUD  
204S  
206S  
118A 10J42 to 5J13  
CASE FRONT - REAR VIEW  
BLOWER BAFLE - SIDE OPPOSITE BLOWER  
GROUND  
210 (TO  
RUN-STOP  
SWITCH)  
12  
11  
10  
9
CONTACTOR  
CONTROL  
6
5
4
KEY  
221 (TO  
RUN-STOP  
SWITCH)  
BATTERY  
CHARGER  
12 NEG  
IGNITION GROUND  
TO STOP ENGINE  
CHOPPER POWER SUPPLY  
20 V DC MEASURED WITH  
CONNECTOR UNPLUGGED  
C
1
2
C
212A (TOBATTERY  
CHARGER CIRCUIT  
BREAKER)  
3
B
TO OIL  
PRESSURE  
SWITCH  
221A (TO START  
BUTTON SWITCH)  
A
120 V AC FOR WIRE FEDER  
42 V AC FOR WIRE FEDER  
21 -WORK SENSE  
3
1
1
2
3
4
TO FUEL  
SHUTOFF  
SOLENOID  
1
2
3
4
REMOTE  
CONTROL  
B
A
D
E
D
CONTACTOR  
CONTROL  
L
K
J
4
IGNITION  
CIRCUIT +12V  
224 (TO HOUR  
METER POS.)  
1
7
3
9
11  
POS  
212A (TO BATTERY  
CHARGER CIRCUIT  
BREAKER)  
3
2
4
E
225 (TO BATTERY  
PC BOARD)  
BATTERY  
CHARGER  
2
M
REMOTE  
CONTROL  
N
I
8
F
F
G
H
224A  
ENGINE SIDE  
LEAD ENTRY VIEW  
ENGINE SIDE  
LEAD ENTRY VIEW  
7
1
23  
25  
NEG  
TWISTED PAIR - PWM SIGNAL  
12 V DC MEASURED WITH  
CONNECTOR UNPLUGGED  
WELDER HARNESS SIDE  
LEAD ENTRY VIEW  
WELDER HARNESS SIDE  
LEAD ENTRY VIEW  
GROUND  
KEY  
POS  
KEY  
ENGINE CONECTOR BLOCK  
ONAN P216 ENGINE  
ENGINE CONECTOR BLOCK  
KOHLER CH20 ENGINE  
TYPICAL MOLEX  
CONNECTOR  
P50 - LEAD END VIEW  
FRONT VIEW OF AMPHENOLS  
G3817  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
G-5  
G-5  
ELECTRICAL DIAGRAMS  
ENHANCED  
WIRING DIAGRAM  
SCHEMATIC - COMPLETE MACHINE  
CURRENT LEVEL FEED BACK  
SIGNAL TO WELD CONTROL  
PC BOARD  
IGBT MODULE - EMMITTER  
IS COMMON TO HEATSINK  
D4  
E
SHUNT  
50MV=400 AMPS  
POSITIVE  
OUTPUT  
TERMINAL  
L1 CHOKE  
D1 - THREE PHASE BRIDGE RECTIFIER  
C
13  
14  
CURRENT LEVEL  
FEED BACK SIGNAL  
206S 204S  
GATE SIGNAL  
C1  
2400uf  
100vdc  
C2  
2400uf  
100vdc  
250 OHMS  
25 W  
206A  
206B  
11  
12  
CHOPPER  
PC BOARD  
25 23  
D2 DIODE  
MODULE  
20V DC  
BY-PASS  
PC BOARD  
WIREFEEDER  
VOLTMETER  
POLARITY  
SWITCH  
R3  
W1  
21  
PWM SIGNAL FROM  
WELD CONTROL  
PC BOARD  
208  
208A  
NEGATIVE  
OUTPUT  
TERMINAL  
W2  
TWO POLE 3600 RPM ALTERNATOR  
W3  
3
120 V AC  
SLIP RINGS  
200A  
AC  
POWER  
200  
5
240 V AC  
50 V DC  
GND E  
23  
25  
11  
12  
120 V AC  
+
204S  
206S  
208B  
C3  
800uf  
150vdc  
6
5V  
D3  
105A  
105A  
41  
ANALOG  
POWER PC  
BOARD  
ARC VOLTAGE FEEDBACK  
OUTPUT  
R1  
CONTROL 10K  
15V  
115A  
115A  
101A  
WELD CONTROL  
PC BOARD  
COM  
101A  
15V  
42 VOLT AC  
WIRE FEEDER  
POWER  
201  
10 V  
116A  
116A  
77  
76  
ROTOR FIELD  
15V TO GND.  
5H  
118A  
118A  
0-10 V  
0 V  
42  
250  
251  
IDLER SWITCH  
5L  
0 V  
10 V  
75  
13 14  
15 V  
15 V  
42 VOLT AC  
POWER FOR  
ROTOR FIELD CIRCUIT  
77A  
76A  
75A  
279  
278  
WELD TERMINALS  
SWITCH  
2
4
REMOTE  
CONTROL 10K  
-15 V (W/O POT.)  
0 V  
0 V  
214  
218  
CV  
PIPE  
CC  
MODE  
SWITCH  
7
ARC  
CONTROL 10K  
220  
222  
R2  
TIG  
9
277  
80V DC BUS VOLTAGE  
TOROID-  
SENSES WELD  
CURRENT AND  
AC POWER TO  
ACTIVATE IDLER  
260A  
261A  
210D  
232  
25A BATERY  
CIRCUIT BREAKER  
THERMOSTAT ON  
CHOPPER MODULE  
NORMALLY CLOSED  
BATERY CHARGER  
TROUBLE LIGHT  
DISPLAY  
233  
210D  
212  
209  
229  
228  
+
IDLER COIL - PULLS TO  
LOW IDLE  
0 - .1V WHEN ON  
RUN-STOP SWITCH  
SHOWN IN RUN POS.  
BATTERY  
PC BOARD  
THERMAL  
SHUTDOWN  
DISPLAY  
215  
5F  
15 Ω  
12 VOLT  
BATTERY  
230  
231  
BATTERY  
CHARGING  
MODULE  
221  
210C  
200  
5K  
KOHLER  
IGNITION  
MODULE  
ROTOR  
FLASHING  
FRAME  
GROUND  
210B  
START BUTTON  
SWITCH  
211  
225  
224B  
12 - 14 V  
ENGINE  
STARTER  
SOLENOID  
210  
ENGINE DIODES  
ENGINE OIL PRESSURE SWITCH  
OPENS ON LOW OIL PRESSURE  
KOHLER FUEL  
SHUTOFF  
SOLENOID  
ENGINE  
STARTER  
224  
HOUR METER  
ONAN  
IGNITION  
MODULE  
+
C
L11480  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
G-6  
G-6  
ELECTRICAL DIAGRAMS  
SCHEMATIC - ANALOG CONTROL POWER SUPPLY  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
G-7  
G-7  
ELECTRICAL DIAGRAMS  
SCHEMATIC - BATTERY PRINTED CIRCUIT BOARD  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
G-8  
G-8  
ELECTRICAL DIAGRAMS  
SCHEMATIC - BYPASS PRINTED CIRCUIT BOARD  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
G-9  
G-9  
ELECTRICAL DIAGRAMS  
SCHEMATIC - CHOPPER PRINTED CIRCUIT BOARD  
M 1 9 4 6 2  
+ 1 5  
R 3  
R 1 0  
1 0 . 0  
5 6 2  
D 6  
t o  
+
c a p  
1 . 0 A  
3 0 V  
R 1 1  
1
8
VS  
VS  
1 0 . 0  
2
5
8
1
1
1 4  
C 5  
X1  
2
7
IN  
C 1  
C 2  
C 3 C 4  
O U T  
3
R 4  
R 1 9  
4 7 5  
R 1 3  
1 0 . 0  
G 1  
3
4
6
N C  
G N D  
O U T  
1 . 0 0 K  
6
G 2  
G 3  
G 4  
G 5  
5
A1  
C 3  
G N D  
D Z1  
9
R 1 5  
1 0 . 0  
0 . 1  
M IC 4 4 5 1 B N  
5 . 1 V  
D 7  
D Z3  
1 2  
5 0 V  
M 1 6 1 0 0 - 3 9  
1 W  
1 . 0 A  
4 . 7 5 K  
1 6 V  
1 W  
3 0 V  
1 5  
+ 1 5  
R 1 7  
1 0 . 0  
E 2  
E 1  
E 3  
E 4  
E 5  
1
4
7
1 0  
1 3  
c o m  
t o h e a t s in k  
B 7  
1
8
VS  
VS  
R 5  
C 4  
1 . 0  
C 6  
0 . 1  
C 7  
c o m  
X1  
M IC 4 4 5 1 B N  
G N D G N D  
t o  
+
c a p  
1 0 . 0  
0 . 1  
6 3 V  
5 0 V  
5 0 V  
R 6  
1 . 2 1 K  
1 0 . 0  
2
5
8
C 3 C 4  
1
1
1 4  
C 5  
P W M  
4
5
C 1  
C 2  
3
R 7  
G 1  
O C I1  
IN P U T  
8
7
6
1 0 . 0  
6
2
G 2  
G 3  
G 4  
G 5  
A2  
9
R 8  
M 1 6 1 0 0 - 3 9  
1 2  
1 0 . 0  
4 . 7 5 K  
1 5  
c o m  
N C  
N C  
R 9  
E 2  
E 1  
E 3  
E 4  
E 5  
3
1
4
5
1 0 . 0  
1
4
7
1 0  
1 3  
B 3  
c o m  
t o h e a t s in k  
+ 1 5  
c o m  
D 5  
1 5 0 V  
8 A  
Q 1  
R 1 4  
D 1  
D 2  
1 5 t o 3 2 Va c  
4 . 7 5 K  
R 1  
R 1 6  
4 . 7 5 K  
+
B 1  
t
C 5  
C 2  
C 1  
. 2 4  
R 1 8  
5 0 0  
5 0 V  
5 0  
0 . 1  
D Z2  
1 6 V  
1 W  
2 5 V  
5 0 V  
4 . 7 5 K  
R 2 0  
B 2  
4 . 7 5 K  
D 4  
D 3  
G E N E R AL IN F O R M ATIO N  
LAS T N O . U S E D  
R - 2 2  
X-  
1
E LE C TR IC AL S YM B O LS P E R E 1 5 3 7  
c o m  
C -  
D -  
7
7
O C I-  
D Z -  
1
C APAC ITO R S  
R E S IS TO R S  
D IO D E S  
=
M F D  
(
. 0 2 2 / 5 0 V  
1 / 4 W  
U N LE S S O TH E R W IS E S P E C IF IE D )  
U N LE S S O TH E R W IS E S P E C IF IE D )  
3
LAB E LS  
=
O h m s  
(
N O TE S  
:
=
1 A, 4 0 0 V  
(U N LE S S O TH E R W IS E S P E C IF IE D )  
S U P P LY  
VO LTAG E N E T  
N . A. S IN C E C O M P O N E N TS O R C IR C U ITR Y O N  
A
P R IN TE D C IR C U IT B O AR D M AY C H AN G E  
C O M P LE TE B O AR D, TH IS D IAG R AM M AY  
P O W E R S U P P LY S O U R C E P O IN T  
C O M M O N C O N N E C TIO N  
W ITH O U T AF F E C TIN G TH E IN TE R C H AN G E AB ILITY O F  
A
N O T S H O W TH E E XAC T C O M P O N E N TS O R C IR C U ITR Y O F C O N TR O LS H AVIN G  
N U M B E R .  
A
C O M M O N C O D E  
F R AM E C O N N E C TIO N  
F ILE N AM E : M 1 9 4 6 2 _ 1 B A  
E AR TH G R O U N D C O N N E C TIO N  
TH IS S H E E T C O N TAIN S P R O P R IE TAR Y IN F O R M ATIO N O W N E D B Y  
TH E LIN C O LN E LE C TR IC C O .  
AN D IS N O T TO B E R E P R O D U C E D, D IS C LO S E D O R U S E D W ITH O U T TH E E XP R E S S P E R M IS S IO N O F  
TH E LIN C O LN E LE C TR IC C O .  
U N LE S S O TH E R W IS E S P E C IF IE D TO LE R AN C E  
O N H O LE S S IZ E S P E R E - 2 0 5 6  
C
h ’g . S h t . N o .  
e
E Q U IP.  
TYP E  
C H O P P E R , 3 0 0 AM P  
S C H E M ATIC  
TH E LIN C O LN E LE C TR IC C O .  
C LE VE LAN D, O H IO U. S . A.  
XC - R W  
O N  
O N  
2
P LAC E D E C IM ALS IS  
P LAC E D E C IM ALS IS  
+
. O 2  
3
+
. O O 2  
4 - 1 4 - 2 0 0 0  
S U B J E C T  
O N ALL AN G LE S IS  
+
. 5 O F  
A
D E G R E E  
N O N E  
S C ALE  
M ATE R IAL TO LE R AN C E ("t ") TO AG R E E  
W ITH P U B LIS H E D S TAN DAR D S  
S H T.  
LC  
3 / 2 6 / 9 9  
C H K.  
S U P ’S ’D ’G .  
M
1 9 4 6 2  
D R .  
DATE  
N O .  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
G-10  
G-10  
ELECTRICAL DIAGRAMS  
SCHEMATIC - DISPLAY PRINTED CIRCUIT BOARD  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
G-11  
G-11  
ELECTRICAL DIAGRAMS  
SCHEMATIC - WELD CONTROL PRINTED CIRCUIT BOARD - SHEET 1  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
G-12  
G-12  
ELECTRICAL DIAGRAMS  
SCHEMATIC - WELD CONTROL PRINTED CIRCUIT BOARD - SHEET 2  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
G-13  
G-13  
ELECTRICAL DIAGRAMS  
SCHEMATIC - WELD CONTROL PRINTED CIRCUIT BOARD - SHEET 3  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
G-14  
G-14  
ELECTRICAL DIAGRAMS  
SCHEMATIC - WELD CONTROL PRINTED CIRCUIT BOARD - SHEET 4  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
G-15  
G-15  
ELECTRICAL DIAGRAMS  
SCHEMATIC - WELD CONTROL PRINTED CIRCUIT BOARD - SHEET 5  
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.  
RANGER 250  
Download from Www.Somanuals.com. All Manuals Search And Download.  
 
SVM ERROR REPORTING FORM  
We need to know if there are errors in our manuals. We also value any suggestions as to  
additional tests or procedures that would make this SVM a better tool for you.  
If you discover new or different “Problems or Symptoms” that are not covered in the three col-  
umn troubleshooting chart, please share this information with us. Please include the  
machine’s code number and how the problem was resolved.  
Thank You,  
Technical Services Group  
Lincoln Electric Co.  
22801 ST. Clair Ave.  
Cleveland, Ohio 44117-1199  
FAX 216-481-2309  
SVM Number ___________________________  
Page Number if necessary__________________  
Your Company__________________________  
Your Name_____________________________  
Please give detailed description below:  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
___________________________________________________________________________  
SD287 01/99  
Download from Www.Somanuals.com. All Manuals Search And Download.  

KWC Indoor Furnishings 11253033006 User Manual
Lego Games 79118 User Manual
LG Electronics DVD Recorder RCT689H User Manual
Lochinvar Water Heater BF User Manual
LOREX Technology Security Camera L15LD420 Series User Manual
Masterbuilt Smoker 20070210 User Manual
Maytag Clothes Dryer MD7500 User Manual
Metabo Cordless Drill 602192520 User Manual
Meyer Sound Portable Speaker MILO 60 User Manual
M S Cash Drawer Printer A794 User Manual