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IM919
®
March, 2008
Ranger 250
For use with machines having Code Numbers:
11401, 11421, 11422
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
Copyright © 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
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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.
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.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.
fumes and gases.When welding, keep
your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control.
ventilation and/or exhaust at the arc to keep
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.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe-
cific welding procedure and applicaiton involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.
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. 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 prod-
ucts.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.d. 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.
5.e. Read and understand the manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
If this is not possible, cover them to prevent
process used and properly operating
the welding sparks from starting a fire.
regulators designed for the gas and
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.
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.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
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.
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.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the 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 cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
6.h. Also see item 1.c.
6.I. Read and folllow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
Jan, 07
6.j. Do not use a welding power source for pipe thawing.
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SAFETY
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
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 dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode 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 sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique 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
defonctionnement.
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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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 lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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 nʼimporte quelle partie
du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du ray-
onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-
er à lʼinterrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, 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
zones où lʼon pique le laitier.
Mar. ʻ93
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for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Thank You
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
for any updated information.
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Machine Specifications ........................................................................................................A-2
Safety Precautions. ..............................................................................................................A-3
Location and Ventilation................................................................................................A-3
Stacking ........................................................................................................................A-3
Angle of Operation ........................................................................................................A-3
Lifting.............................................................................................................................A-3
Additional Safety Precautions .......................................................................................A-3
High Altitude Operation.................................................................................................A-3
High Temperature Operation ........................................................................................A-3
Towing...........................................................................................................................A-4
Vehicle Mounting...........................................................................................................A-4
Pre-Operation Engine Service..............................................................................................A-4
Oil..................................................................................................................................A-4
Fuel ...............................................................................................................................A-4
Engine Coolant..............................................................................................................A-4
Battery Connections......................................................................................................A-4
Muffler Outlet Pipe ........................................................................................................A-5
Spark Arrester...............................................................................................................A-5
High Frequency Generators for Tig Applications ..........................................................A-5
Remote Control.............................................................................................................A-5
Electrical Connections..........................................................................................................A-5
Machine Grounding.......................................................................................................A-5
Welding Terminals ........................................................................................................A-6
Welding Output Cables .................................................................................................A-6
Cable Installation...........................................................................................................A-6
Auxiliary Power Receptacles and Plugs...............................................................................A-6
Standby Power Connections................................................................................................A-6
Premises Wiring...................................................................................................................A-7
Connection of Lincoln Electric Wire Feeders................................................................A-8, A-9
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
General Description..............................................................................................................B-1
Design Features...................................................................................................................B-1
Engine Operation ..........................................................................................................B-1
Fuel ...............................................................................................................................B-1
Welding Controls..................................................................................................................B-2
Engine Controls....................................................................................................................B-3
Starting and Stopping the Engine .................................................................................B-3
Stopping .......................................................................................................................B-4
Welding Operation................................................................................................................B-4
Duty Cycle.....................................................................................................................B-4
DC Stick Welding ..........................................................................................................B-4
Constant Current (Stick) Welding..................................................................................B-4
Downhill Pipe Welding ..................................................................................................B-4
Fuel Consumption.........................................................................................................B-4
Tig Welding ...................................................................................................................B-5
Typical Current Ranges for Tungsten Electrodes .........................................................B-5
Wire Welding-CV...........................................................................................................B-5
Arc Gouging ..................................................................................................................B-6
Auxiliary Power .............................................................................................................B-6
Simultaneous Welding and Auxiliary Power Loads.......................................................B-6
Extension Cord Recommendations...............................................................................B-6
________________________________________________________________________________
Accessories.....................................................................................................Section C
Recommended Optional Equipment.....................................................................C-1
________________________________________________________________________
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TABLE OF CONTENTS
Maintenance......................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance......................................................................................D-1
Kohler / Robin-Subaru Engine Maintenance Components....................................D-1
Kohler Engine .......................................................................................................D-1
Subaru Robin Engine ............................................................................................D-1
Engine Oil Change..........................................................................................D-2
Engine Oil Refill Capacities (Kohler / Subaru Robin)......................................D-2
Oil Filter Change.............................................................................................D-2
Air Cleaner Service.........................................................................................D-2
Air Pre-Cleaner Service ..................................................................................D-2
Air Filter Paper Element..................................................................................D-3
Spark Plug ......................................................................................................D-3
Spark Plug Service .........................................................................................D-3
Fuel Filter........................................................................................................D-4
Engine Adjustment..........................................................................................D-4
Battery Maintenance .......................................................................................D-4
Option Spark Arrestor......................................................................................D-4
Welder / Generator Maintenance ........................................................................D-5
Storage ...........................................................................................................D-5
Cleaning..........................................................................................................D-5
Brush Removal and Replacement ..................................................................D-5
________________________________________________________________________
Troubleshooting..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Troubleshooting Guide..........................................................................................E-3
Troubleshooting Guide..........................................................................................E-4
Troubleshooting Guide ..........................................................................................E-5
________________________________________________________________________
Diagrams & Dimension Print..........................................................................Section F
________________________________________________________________________
Parts List .....................................................................................................P-490 Series
________________________________________________________________________
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - Ranger® 250 ( K1725-10, K1725-11, K1725-12)
INPUT - GASOLINE ENGINE
Make/Model Description Horsepower Operating Displacement cu. in.(cu. cm) Starting
Capacities
@ 3600 RPM SPEED Bore x Stroke in.(mm)
System
12VDC Battery
and starter
K1725-10, -11
Kohler CH23S
OHV
Fuel: 12gal.(45.4L)
Oil: 2.0qts.(1.9L)
41.1 (674)
High
23 HP
22 HP
3.15x 2.64 (80x67)
2 Cylinder
3700RPM
Push Button
4 Cycle
Full Load
3500RPM
Air Cooled
Starter
Gasoline
Engine
K1725-12
Subaru Robin
EH65
Fuel: 12gal.(45.4L)
Oil: 1.6qts.(1.5L)
39.8 (653)
Group 58 Battery
(435 cold
Low Idle
3.15x 2.56 (80x65)
2400RPM
crank amps)
OHV
RATED OUTPUT @ 104°F(40C°) - 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
28 Volts at 250 Amps
40 to 250 Amps
100%
20 to 250 Amps
60 Volts
CV WIRE DC Output
28 Volts at 250 Amps
27 Volts at 275 Amps
14 to 28 volts
100%
60%
CV WIRE DC Output
CV WIRE Output Range
RATED OUTPUT @ 104°F(40C°) - GENERATOR
1
Auxiliary Power
10,500 Watts Peak, 9500 Watts Continuous, 60 Hz
120/240 Volts
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
DEPTH
WEIGHT
30.00** in.
762.0 mm
21.50 in.
42.25 in.
546.0 mm
1073.0 mm
500 lbs. (227kg.)
**Top of enclosure, add 6.4” (164mm) for exhaust.
ENGINE COMPONENTS
FUEL SYSTEM
LUBRICATION
VALVE LIFTERS
GOVERNOR
Mechanical Fuel Pump (Kohler)
Additional electric fuel lift
pump on K1725-11 Kohler Model
Diaphram pressure pulse pump
(Subaru Robin)
Mechanical Governor
5% Regulation (Kohler)
Hydraulic (Kohler)
Full Pressure
with Full Flow Filter
Centrifugal Flywheel
(Subaru Robin)
Solid (Subaru Robin)
AIR CLEANER
ENGINE IDLER
MUFFLER
ENGINE PROTECTION
Shutdown on low oil
pressure.
Low noise Muffler: Top outlet
can be rotated. Made from
long life, aluminized steel.
Dual Element
Automatic Idler
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
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A-2
A-2
INSTALLATION
MACHINE SPECIFICATIONS - Ranger® 250 ( K1725-10, K1725-11, K1725-12)
RECEPTACLES AND CIRCUIT BREAKERS
RECEPTACLES
AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS
(2) 120VAC Duplex (5-20R)
(1) 120/240VAC Dual Voltage
Full KVA (14-50R)
Two 20AMP for Two Duplex Receptacle 20AMP for Battery Charging Circuit
One 50AMP for Dual Voltage (2-Pole)
15AMP for 42V Wire Feeder Power
RANGER® 250
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A-3
A-3
INSTALLATION
LIFTING
SAFETY PRECAUTIONS
The RANGER® 250 weighs approximately 575 lbs.
with a full tank of gasoline. A lift bail is mounted to the
machine and should always be used when lifting the
machine.
WARNING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
ADDITIONAL SAFETY PRECAUTIONS
WARNING
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Lift only with equipment of
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
adequate lifting capacity.
• Be sure machine is stable
when lifting.
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trail-
er or gas cylinder.
• Use in open, well ventilated areas or
vent exhaust outside.
FALLING
EQUIPMENT can damaged.
cause injury. • Do not operate machine while
suspended from lift bale.
• Do not lift machine if lift bale is
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
------------------------------------------------------------------------
• Stop engine before servicing.
HIGH ALTITUDE OPERATION
• Keep away from moving parts.
------------------------------------------------------------------------
At higher altitudes, Welder output de-rating may be
necessary. For maximum rating, de-rate the welder
output 3.5% for every 1000 ft. (305m) above 3000 ft.
(914m). If operation will consistently be at altitudes
above 5,000 ft. (1525m), a carburetor jet designed for
high altitudes should be installed. This will result in
better fuel economy, cleaner exhaust and longer
spark plug life. It will not give increased power.
Contact your local authorized engine service shop for
high altitude jet kits that are available from the engine
manufacturer.
• See additional warning information at
front of this operatorʼs manual.
-----------------------------------------------------------
• Only qualified personnel should install,
use, or service this equipment.
------------------------------------------------------------
LOCATION AND VENTILATION
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 prop-
erly vented to an outside area.
CAUTION
Do not operate with a high altitude jet installed at
altitudes below 5000 ft. This will result in the
engine running too lean and result in higher
engine operating temperatures which can shorten
engine life.
STACKING
Ranger® 250 machines cannot be stacked.
------------------------------------------------------------------------
HIGH TEMPERATURE OPERATION
At temperatures above 104°F(40°C),Welder output
de-rating is necessary. For maximum output ratings,
de-rate the welder output 2 Volts for every 50°F(10°C)
above 104°F(40°C).
ANGLE OF OPERATION
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.
When operating the welder at an angle, the effective
fuel capacity will be slightly less than the specified 12
gallons.
RANGER® 250
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A-4
A-4
INSTALLATION
TOWING
WARNING
The recommended trailer for use with this equipment
(1)
• Stop engine while fueling.
• Do not smoke when fueling.
for road, in-plant and yard towing by a vehicle is
Lincolnʼs K957-1. If the user adapts a non-Lincoln
trailer, he must assume responsibility that the method
of attachment and usage does not result in a safety
hazard nor damage the welding equipment. Some of
the factors to be considered are as follows:
• Keep sparks and flame away
from tank.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
fumes to clear before starting
engine.
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
GASOLINE
can cause fire
or explosion.
• Do not overfill tank, fuel expan-
sion may cause overflow.
GASOLINE FUEL ONLY
2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
------------------------------------------------------------------------
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.
OIL
The RANGER® 250 is shipped with the engine crankcase filled with
high quality SAE 10W-30 oil. Check the oil level before starting the
engine. If it is not up to the full mark on the dip stick, add oil as
required. Check the oil level every four hours of running time during
the first 25 running hours. Refer to the engine Operatorʼs Manual for
specific oil recommendations and break-in information. The oil
change interval is dependent on the quality of the oil and the operat-
ing environment. Refer to the Engine Operatorʼs Manual for the
proper service and maintenance intervals.
4. Typical conditions of use, i.e., travel speed; rough-
ness of surface on which the trailer will be operat-
ed; environmental conditions.
(1)
5. Conformance with federal, state and local laws.
(1) Consult applicable federal, state and local laws
regarding specific requirements for use on public
highways.
VEHICLE MOUNTING
FUEL
CAUTION
WARNING
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
USE GASOLINE FUEL ONLY
Fill the fuel tank with clean, fresh fuel. The capaci-
ty of the fuel tank is 12 gallons (45.4 liters). When
the fuel gauge reads empty the tank contains
approximately 2 gallons (7.6 liters) of reserve fuel.
• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.
NOTE: The fuel tank is mounted below the engine
so a fuel shutoff valve is not required.
• Distribute, balance and secure loads so vehicle
is stable under conditions of use.
-----------------------------------------------------------------------
ENGINE COOLING SYSTEM
• Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
vehicle.
Air to cool the engine is drawn in 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 surface.
• Follow vehicle manufactureʼs instructions.
------------------------------------------------------------------------
BATTERY CONNECTION
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instruc-
tions supplied with this machine.
CAUTION
Use caution as the electrolyte is a strong acid that
can burn skin and damage eyes.
------------------------------------------------------------------------
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A-5
A-5
INSTALLATION
T
he RANGER® 250 is shipped with the negative battery
The 14-pin connector is used to directly connect a
wire feeder or TIG Module (K930-2) control cable. 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.
cable disconnected. Make certain that the RUN-STOP
switch is in the STOP position. Remove the two screws
from the rear battery tray using a screwdriver or a 3/8"
socket. Attach the negative battery cable to the negative
battery terminal and tighten using a 1/2" socket or
wrench.
NOTE: This machine is furnished with a wet charged bat-
tery; if unused for several months, the battery may
require a booster charge. Be careful to charge the bat-
tery with the correct polarity.
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.
----------------------------------------------------------------------------
ELECTRICAL CONNECTIONS
MUFFLER OUTLET PIPE
MACHINE GROUNDING
Using the clamp provided secure the outlet pipe to the
outlet tube with the pipe positioned such that it will direct
the exhaust in the desired direction. Tighten using a
9/16" socket or wrench.
Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.)
SPARK ARRESTER
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:
Some federal, state or local laws may require that gaso-
line or diesel engines be equipped with exhaust spark
arresters when they are operated in certain locations
where unarrested sparks may present a fire hazard. The
standard muffler included with this welder does not quali-
fy as a spark arrester. When required by local regula-
tions, a suitable spark arrester, such as the K1898-1
must be installed and properly maintained.
WARNING
1. Be grounded to the frame of the welder using a
grounded type plug.
2. Be double insulated.
CAUTION
Do not ground the machine to a pipe that carries
explosive or combustible material.
An incorrect spark arrester may lead to damage to
the engine or adversely affect performance.
------------------------------------------------------------------------
When this welder is mounted on a truck or trailer, its
frame must be electrically bonded to the metal frame
of the vehicle, use a #8 or larger copper wire connect-
ed between the machine grounding stud and frame of
the vehicle. When this engine driven welder is con-
nected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
ground. See further connection instructions in the sec-
tion entitled "Standby Power Connections" as well as
the article on grounding in the latest U.S. National
Electrical Code and the local code.
------------------------------------------------------------------------
HIGH FREQUENCY GENERATORS FOR
TIG APPLICATIONS
The K930-2 TIG Module is suitable for use with the
Ranger® 250. The Ranger® 250 and any high fre-
quency generating equipment must be properly
grounded. See the K930-2 Operating Manual for
completed instructions on installation, operation, and
maintenance.
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 insulat-
ed joints, or to the metal framework of a building
which has been effectively grounded.
REMOTE CONTROL
The Ranger® 250 is equipped with a 6-pin and a 14-
pin connector. The 6 pin connector is for connecting
the K857 or K857-1 Remote Control (optional) or for
TIG welding, the K870 foot Amptrol or the K963-3
hand Amptrol.
The U.S. National Electrical Code lists a number of
alternate means of grounding electrical equipment. A
machine grounding stud marked with the symbol
is provided on the front of the welder.
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
control at the welder to remote control .
RANGER® 250
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A-6
A-6
INSTALLATION
The auxiliary power capacity is 10,500 Watts Peak, 9500
Watts Continuous of 60 Hz, single phase power. The auxiliary
power capacity rating in watts is equivalent to volt-amperes at
unity power factor. The max permissible current of the 240
VAC output is 40 Amps. The 240 VAC output can be split to
provide two separate 120 VAC outputs with a max permissible
current of 40 Amps per output to two separate 120 VAC
branch circuits (these circuits cannot be paralleled). Output
voltage is within 10% at all loads up to rated capacity. All
auxiliary power is protected by circuit breakers.
WELDING TERMINALS
The Ranger® 250 is equipped with a toggle switch for select-
ing "hot" welding terminal when in the "WELD TERMINALS
ON" position or "cold" welding terminal when in the "REMOTE-
LY CONTROLLED" position.
WELDING OUTPUT CABLES
With the engine off connect the electrode and work cables to
the output studs. The welding process dictates the polarity of
the electrode cable. These connections should be checked
periodically and tightened with a 3/4" wrench.
The 120 V auxiliary power receptacles should only be used
with three wire grounded type plugs or approved double insu-
lated 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.
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.
TABLE A-1
NOTE: The 240 V receptacle has two 120 V circuits, but are of
TOTAL COMBINED LENGTH OF
opposite polarities and cannot be paralleled.
ELECTRODE AND WORK CABLES
STANDBY POWER CONNECTIONS
Cable Size for
The RANGER® 250 is suitable for temporary, standby or
emergency power using the engine manufacturerʼs recom-
mended maintenance schedule.
Cable Length
250 Amps
100% Duty Cycle
1 AWG
0-100 Ft. (0-31 meters)
The RANGER® 250 can be permanently installed as a stand-
by power unit for 240 VAC, 3 wire, single phase, 40 amp ser-
vice. 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 electri-
cal codes.
1 AWG
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
1/0 AWG
CABLE INSTALLATION
Install the welding cables to your RANGER® 250 as follows.
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 customerʼs
premises disconnect and service over current protection.
1. The engine must be OFF to install welding cables.
2. Remove the flanged nuts from the output terminals.
3. Connect the electrode holder and work cables to the weld
output terminals. The terminals are identified on the case
front.
2. Take necessary steps to assure load is limited to the capac-
ity of the RANGER® 250 by installing a 40 amp, 240 VAC
double pole circuit breaker. Maximum rated load for each
leg of the 240 VAC auxiliary is 40 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 over-
heating of the RANGER® 250 engine and/or alternator
windings.
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.
CAUTION
• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.
• Do not cross the welding cables at the output terminal
connection. Keep the cables isolated and separate from
one another.
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.)
-----------------------------------------------------------------------------------
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.
4. Plug this cable into the 50 Amp, 120/240 Volt receptacle on
the RANGER® 250 case front.
RANGER® 250
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A-7
A-7
INSTALLATION
CONNECTION OF RANGER® 250 TO PREMISES
240 VOLT
GROUNDED CONDUCTOR
POWER
COMPANY
METER
240 Volt
60 Hz.
3-Wire
Service
120 VOLT
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
50AMP
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. 6 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
electrical 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 cir
cuit breaker is connected between the generator power and the utility meter.
RANGER® 250
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A-8
A-8
INSTALLATION
• Control Cable Model:
CONNECTION OF LINCOLN ELEC-
TRIC WIRE FEEDERS
Connect Control Cable between Engine Welder and
Feeder.
Connection of LN-7 or LN-8 to the Ranger® 250
Set the "WELD TERMINALS" switch to "REMOTELY
CONTROLLED"
1. Shut the welder off.
• Set the MODE switch to the "CV-WIRE " position.
2. Connect the LN-7 or LN-8 per instructions on the
appropriate connection diagram in Section F
• Set the "WIRE FEEDER VOLTMETER" switch to
either "+" or "-" as required by the electrode polarity
being used.
3. Set the "WIRE FEEDER VOLTMETER" switch to
either "+" or "-" as required by the electrode being
used.
• Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
4. Set the "MODE" switch to the "CV WIRE " posi-
tion.
• Set the "IDLE" switch to the "AUTO" position
5. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
Connection of the LN-25 to the Ranger® 250
The LN-25 with or without an internal contactor may
be used with the Ranger® 250. See the appropriate
connection diagram in Section F.
6 Set the "WELD TERMINALS" switch to the
"REMOTELY CONTROLLED" position.
7. Set the "IDLE" switch to the "HIGH" position.
1. Shut the welder off.
Connection of LN-15 to the Ranger® 250
2. For electrode Positive, connect the electrode
cable from the LN-25 to the "+" terminal of the
welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the elec-
trode cable from the LN-25 to the "-" terminal of
the welder and work cable to the "+" terminal of
the welder.
These connections instructions apply to both the LN-
15 Across The-Arc and Control Cable models. The
LN-15 has an internal contactor and the electrode is
not energized until the gun trigger is closed. When the
gun trigger is closed the wire will begin to feed and the
welding process is started.
3. Attach the single lead from the front of the LN-25
to work using the spring clip at the end of the lead.
This is a control lead to supply current to the wire
feeder motor; it does not carry welding current.
• Shut the welder off.
• For electrode Positive, connect the electrode cable
to the "+" terminal of the welder and work cable to
the "-" terminal of the welder. For electrode
Negative, connect the electrode cable to the "-" ter-
minal of the welder and work cable to the "+" termi-
nal of the welder.
4. Set the MODE switch to the "CV-WIRE " position.
5. Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON"
• Across The-Arc Model:
6. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
Attach the single lead from the front of the LN-15 to
work using the spring clip at the end of the lead. This
is a control lead to supply current to the wire feeder
motor; it does not carry welding current.
Set the "WELD TERMINALS" switch to "WELD TER-
MINALS ON"
RANGER® 250
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A-9
A-9
INSTALLATION
7. Set the "IDLE" switch to the "AUTO" position.
When not welding, the Ranger® 250 engine will
be at the low idle speed. If you are using an LN-25
with an internal contactor, the electrode is not
energized until the gun trigger is closed.
8. When the gun trigger is closed, the current sens-
ing circuit will cause the Ranger® 250 engine to
go to the high idle speed, the wire will begin to
feed and the welding process started. When weld-
ing is stopped, the engine will revert to low idle
speed after approximately 12 seconds unless
welding is resumed.
Connection of LN-742, K487-25 Spool Gun, and
Cobramatic to Ranger® 250
1. Shut the welder off.
2. Connect per instructions on the appropriate con-
nection diagram in Section F.
RANGER® 250
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B-1
B-1
OPERATION
SAFETY PRECAUTIONS
DESIGN FEATURES
Read and understand this entire section before
ENGINE OPERATION
operating your Ranger® 250.
Before Starting the Engine:
Do not attempt to use this equipment until you
have thoroughly read all operating and mainte-
nance manuals supplied with your machine. They
include important safety precautions, detailed
engine starting, operating and maintenance
instructions and parts lists.
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.
ELECTRIC SHOCK can kill.
•Do not touch electrically live parts
such as output terminals or internal
wiring.
3. Add oil (if necessary) to bring the level up to the full
mark. Do not overfill. Close engine door.
4. See Engine Ownerʼs Manual for specific oil recom-
mendations.
•Insulate yourself from the work and
ground.
ADD FUEL
•Always wear dry insulating gloves.
------------------------------------------------------------------------
WARNING
ENGINE EXHAUST can kill.
•Use in open, well ventilated areas or
vent exhaust outside
GASOLINE can cause fire or
explosion.
• Stop engine when fueling.
•Do not stack anything near the
engine.
• Do not smoke when fueling.
• Do not overfill tank.
------------------------------------------------------------------------
• Avoid contact with skin or
breathing of vapor.
MOVING PARTS can injure.
•Do not operate with doors open or
guards off.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------
1. Remove the fuel tank cap.
•Stop engine before servicing.
2. Fill the tank approximately 4 inches (100mm) from
the top of the filler neck to allow for fuel expansion
DO NOT FILL THE TANK TO THE POINT OF
OVERFLOW.
•Keep away from moving parts
------------------------------------------------------------------------
• Only qualified personnel should operate this
equipment.
3. Replace the fuel cap and tighten securely.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged door
closed and the side panels in place as these pro-
vide maximum protection from moving parts and
insure proper cooling air flow.
4. See Engine Ownerʼs Manual for specific fuel rec-
ommendations.
------------------------------------------------------------------------
GENERAL DESCRIPTION
The Ranger® 250 is a gasoline engine powered DC
multi-process welding power source and 120 / 240
volt AC power generator. The engine drives a genera-
tor that supplies three phase power for the DC weld-
ing circuit and single phase power for the AC auxiliary
outlets. The DC welding control system uses state of
C
the art Chopper Technology
for superior welding
T
R
performance. The Ranger® 250 is not recommended
for pipe thawing.
RANGER® 250
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B-2
B-2
OPERATION
15
14
1
13
12
2
11
10
3
4
9
8
7
6
5
CC-STICK mode: In this mode, the ARC CONTROL dial
sets the short circuit current (arc-force) during stick weld-
ing to adjust for a soft or crisp arc. Increasing the number
from -10(soft) to +10(crisp) increases the short circuit cur-
rent and prevents sticking of the electrode to the plate
while welding. This can also increase spatter. It is recom-
mended that the ARC CONTROL be set to the minimum
number without electrode sticking. Start with a setting at 0.
WELDING CONTROLS:
1. OUTPUT CONTROL: The CONTROL dial
provides continuous control of the welding current or
welding voltage depending on the selected welding
mode. This control is not active in the CC-STICK,
DOWN HILL PIPE, and CV-WIRE modes when a
remote control or wire feeder with remote control is
connected to either the 6 pin or 14 pin Amphenol.
DOWNHILL PIPE MODE: In this mode, the ARC CON-
TROL dial sets the short circuit current (arc force) during
stick welding to adjust for a soft or a more forceful digging
arc (crisp). Increasing the number from -10(soft) to
+10(crisp) increases the short circuit current which results
in a more forceful digging arc. Typically a forceful digging
arc is preferred for root and hot passes. A softer arc is pre-
ferred for fill and cap passes where weld puddle control
and deposition (“stacking” of iron) are key to fast travel
speeds. It is recommended that the ARC CONTROL be
set initially at 0.
2. WELD MODE SELECTOR SWITCH:
(Provides four selectable welding modes)
CV-WIRE
DOWN HILL PIPE
CC-STICK
TOUCH START TIG
3. ARC CONTROL :
The ARC CONTROL WIRE/STICK dial is active in the
WIRE, STICK and DOWN HILL PIPE modes, and has
different functions in these modes. This control is not
active in the TIG mode.
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 pro-
cedure and operator preference. Start with a setting at 0.
RANGER® 250
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B-3
B-3
OPERATION
13. IDLER SWITCH- Has two positions as follows:
1) In the HIGH position, the engine runs at the high
idle speed controlled by the engine governor.
4. WELD OUTPUT TERMINALS WITH
FLANGE NUT:
Provides a connection point for the electrode and
work cables. Output stud covers provided on code 11270
and above.
2) In the AUTO position, the idler operates as follows:
• When switched from HIGH to AUTO or after starting
the engine, the engine will operate at full speed for
approximately 12 seconds and then go to low idle
speed.
5. GROUND STUD: (graphic)
Provides a connection point for connecting the
machine case to earth ground for the safest grounding
procedure.
• When the electrode touches the work or power is
drawn for lights or tools (approximately 100 Watts
minimum), the engine accelerates and operates at
full speed.
6. 14-PIN CONNECTOR:
For attaching wire feeder control cables to the
Ranger® 250. Includes contactor closure circuit, auto-
sensing remote control circuit, and 120V and 42V
power. The remote control circuit operates the same
as the 6-Pin Amphenol.
• When welding ceases or the AC power load is
turned off, a fixed time delay of approximately 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.
7. 6-PIN CONNECTOR:
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 automatically switches the OUTPUT control from
control at the welder to remote control .
• The engine will automatically return to high idle
speed when there is welding load or AC power load
reapplied.
14. ELECTRIC FUEL GAUGE-
The electric fuel gauge gives accurate and reliable
indication as to how much fuel is in the fuel tank.
When using the TOUCH START TIG mode with a
TIG Module connected to the Ranger® 250, the OUT-
PUT control on the front of the Ranger® 250 is used
to set the maximum current range of the CURRENT
CONTROL on the TIG Module.
15. ENGINE HOUR METER –
Displays the total time that the engine has been run-
ning. This meter is useful for scheduling prescribed
maintenance.
8. WELD TERMINALS CONTROL SWITCH:
In the WELD TERMINALS ON position, the output is
electrically hot all the time. In the REMOTELY CON-
TROLLED position, the output is controlled by a wire
feeder or amptrol device, and is electrically off until a
remote switch is depressed.
STARTING AND STOPPING THE ENGINE
1. Remove all plugs connected
to the AC power receptacles.
2. Set IDLER switch to AUTO.
3. Set the RUN/STOP switch to RUN.
4. Pull the choke to the full out position.
9. WIRE FEEDER VOLTMETER SWITCH:
Matches the polarity of the wire feeder voltmeter to
the polarity of the electrode.
5. Press and hold the engine START button until the
engine starts.
ENGINE CONTROLS:
10. RUN/STOP SWITCH - RUN position ener-
gizes 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.
6. Release the engine START button when the engine
starts.
7. Push the choke back in.
8. The engine will run at high idle speed for approxi-
mately 12 seconds and then go to low idle speed.
Allow the engine to warm up at low idle for several
minutes before applying a load and/or switching to
high idle. Allow a longer warm up time in cold
weather.
11. CHOKE - When pulled out, it closes the choke
valve on the engine carburetor for quick starting.
12. START PUSH BUTTON - Energizes the
starter motor to crank the engine.
RANGER® 250
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B-4
B-4
OPERATION
CAUTION
DC STICK WELDING
Operating the starter motor for more than 5 seconds
can damage the motor. If the engine fails to start,
release the switch and wait 10 seconds before opera-
tion 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.
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
The CC-STICK position of the MODE switch is designed for
flat, horizontal and vertical-up welding with all types of elec-
trodes, especially low hydrogen. The output CONTROL dial
adjusts the full output range for stick welding.
-----------------------------------------------------------------------------
NOTE: When starting a Ranger® 250 for the first time, or
after an extended period of time of not operating, it will
take longer than normal because the fuel pump has to fill
the fuel line and carburetor.
The ARC CONTROL dial sets the short circuit current (arc-
force) during stick welding to adjust for a soft or crisp arc.
Increasing the number from -10(soft) to +10(crisp) increases
the short circuit current and prevents sticking of the elec-
trode to the plate while welding. This can also increase spat-
ter. It is recommended that the ARC CONTROL be set to the
minimum number without electrode sticking. Start with the
dial set at 0.
FOR SUBARU ROBIN ENGINES
If engine is already warm starting should be done with
one half or no choke applied.
STOPPING THE ENGINE
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.
DOWNHILL PIPE WELDING
Stop the engine by placing the RUN-STOP in the STOP
position.
This slope controlled setting is intended for "out-of-position"
and "down hill" pipe welding where the operator would like to
control the current level by changing the arc length. The out-
put CONTROL dial adjusts the full output range for pipe
welding. The ARC CONTROL dial sets the short circuit cur-
rent (arc-force) during stick welding to adjust for a soft or
more forceful digging arc (crisp). Increasing the number from
-10(soft) to +10(crisp) increases the short circuit current
which results in a more forceful digging arc. Typically a
forceful digging arc is preferred for root and hot passes. A
softer arc is preferred for fill and cap passes where weld
puddle control and deposition (“stacking” of iron) are key to
fast travel speeds. This can also increase spatter. It is rec-
ommended that the ARC CONTROL be set to the minimum
number without electrode sticking. Start with the dial set at 0.
NOTE: A fuel shut off valve is not required on the
Ranger® 250 because the fuel tank is mounted below the
engine.
WELDER OPERATION
DUTY CYCLE is the percentage of time the load is
being applied in a 10 minute period. For example, a 60%
duty cycle represents 6 minutes of load and 4 minutes of
no load in a 10 minute period.
TYPICAL RANGER® 250 FUEL CONSUMPTION
Subaru Robin EH65
22HP @ 3600 RPM
Gal./Hr (Liters/Hr)
0.5 (1.9)
CH23/EH65 HOURS
Approx. Run Time for
12 Gallon Tank (Hours)
20 / 24
Kohler CH23S
23HP @ 3600 RPM
Gal./Hr (Liters/Hr)
0.6 (2.3)
Low Idle - No Load
2400 R.P.M.
0.8 (3.0)
1.6 (5.9)
1.9 (7.2)
15 / 15
8.6 / 7.5
7.3 / 6.3
High Idle - No Load
3700 R.P.M.
0.8 (3.0)
1.40 (5.3)
1.64 (6.2)
DC Weld Output
250 Amps @ 28 Volts
Auxiliary Power
9,500 Watts Continuous
RANGER® 250
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B-5
B-5
OPERATION
TIG WELDING
When using the TIG Module, the OUTPUT control on the
Ranger® 250 is used to set the maximum range of the
CURRENT CONTROL on the TIG Module or an Amptrol if
connected to the TIG Module.
The TOUCH START TIG setting of the MODE switch is for
DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the
CONTROL dial is first set to the desired current and the tung-
sten 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 establish-
es the arc.
WIRE WELDING-CV
Connect a wire feeder to the Ranger® 250 according to the
instructions in INSTALLATION INSTRUCTIONS Section.
The Ranger® 250 in the CV-WIRE mode, permits it to be
used with a broad range of flux cored wire (Innershield and
Outershield) electrodes and solid wires for MIG welding (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 con-
trol. The proper setting depends on the procedure and oper-
ator preference. Start with the dial set at 0.
The ARC CONTROL is not active in the TIG mode. To STOP
a weld, simply pull the TIG torch away from the work. When
the arc voltage reaches approximately 30 Volts the arc will go
out and the machine will reset the current to the Touch Start
level. To reinitiate the arc, retouch the tungsten to the work
and lift. Alternatively, the weld can be stopped by releasing
the Amptrol or arc start switch.
The Ranger® 250 can be used in a wide variety of DC TIG
welding applications. In general the ʻTouch Startʼ feature
allows contamination free starting without the use of a Hi-fre-
quency unit. If desired, the K930-2 TIG Module can be used
with the Ranger® 250. The settings are for reference.
Listed below are some wires suitable for use on this
machine:
• Innershield - NR-311, NS-3M, NR-207, NR-203 Ni 1%.
• Outershield - 0S-70, 0S-71M.
• Solid wires for MIG welding - .035 (0.9 mm), and .045 (1.1
mm), Super Arc L-50 and L-56, .035 (0.9 mm) and .045
(1.1 mm) Blue Max MIG 308 LS.
Ranger® 250 settings when using the K930-2 TIG Module
with an Amptrol or Arc Start Switch:
• Set the MODE Switch to the TOUCH START TIG setting.
• Set the "IDLER" Switch to the "AUTO" position.
• Set the "WELDING TERMINALS" switch to the "REMOTE-
LY CONTROLLED" position. This will keep the "Solid
State" contactor open and provide a "cold" electrode until
the Amptrol or Arc Start Switch is pressed.
Contact your local authorized Lincoln Electric Distributor or
the Lincoln Electric Company for specific wires used on cer-
tain applications with this machine.
(1)
(2)
TYPICAL CURRENT RANGES
FOR TUNGSTEN ELECTRODES
Tungsten Electrode
Diameter in. (mm)
DCEN (-)
DCEP (+)
Approximate Argon Gas Flow
Flow Rate C.F.H. ( l /min.)
TIG TORCH
Nozzle Size (4), (5)
1%, 2% Thoriated
Tungsten
1%, 2% Thoriated Aluminum
Tungsten
Stainless Steel
.010
(.25)
2-15
5-20
(3)
(3)
(3)
3-8
(2-4)
(3-5)
(3-5)
3-8
(2-4)
(3-5)
(3-5)
#4, #5, #6
0.020
0.040
(.50)
(1.0)
5-10
5-10
5-10
5-10
15-80
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
15-23
(6-8)
11-15
11-15
(5-7)
(5-7)
#6, #7, #8
(7-11)
5/32
3/16
1/4
(4.0)
(4.8)
(6.4)
400-500
500-750
750-1000
40-55
55-80
80-125
21-25
23-27
28-32
(10-12)
(11-13)
(13-15)
13-17
18-22
23-27
(6-8)
#8, #10
(8-10)
(11-13)
(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.
(2) Tungsten electrodes are classified as follows by the American Welding 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.
# 5 = 5/16 in.
# 6 = 3/8 in.
# 7 = 7/16 in.
# 8 = _ in.
(6 mm)
(8 mm)
(10 mm)
(11 mm)
(12.5 mm)
(16 mm)
#10 = 5/8 in.
(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
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B-6
B-6
OPERATION
The auxiliary power capacity is 10,500 Watts Peak,
9500 Watts Continuous of 60 Hz, single phase power.
The auxiliary power capacity rating in watts is equiva-
lent to volt-amperes at unity power factor. The max
permissible current of the 240 VAC output is 40 Amps.
The 240 VAC output can be split to provide two sepa-
rate 120 VAC outputs with a max permissible current
of 40 Amps per output to two separate 120 VAC
branch circuits (these circuits cannot be paralleled).
Output voltage is within 10% at all loads up to rated
capacity. All auxiliary power is protected by circuit
breakers.
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.
Set the CONTROL knob to adjust output current to the
desired level for the gouging electrode being used
according to the ratings in the following table.
Carbon Diameter
Current Range (DC, electrode
positive)
1/8" (3.2mm)
5/32" (4.0mm)
3/16" (4.8mm)
60-90 Amps
The 120 V 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.
90-150 Amps
200-250 Amps
AUXILIARY POWER:
Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
regardless of the welding control settings providing no
welding current is being drawn.
NOTE: The 240 V receptacle has two circuits, each of
which measure 120 V to neutral but are of opposite
polarities and cannot be paralleled.
Simultaneous Welding and Auxiliary Power Loads
The above auxiliary power ratings are with no welding
load. Simultaneous welding and power loads are
specified in the following table. The permissible cur-
rents shown assume that current is being drawn from
either the 120 VAC or 240 VAC supply (not both at the
same time).
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.
Ranger® 250 Simultaneous Welding and Power Loads
Permissible Auxiliary
Permissible Power-Watts
Welding
Current in -Amps
(Unity Power Factor)
Output-Amps
@120 VAC *
@ 240 VAC
80**
60**
46**
36
40
30
23
18
10
9500
7100
5600
4200
2300
0
100
150
200
250
20
* Each duplex receptacle is limited to 20 amps.
** Not to exceed 40 A per 120 VAC branch circuit when splitting the 240 VAC output.
Ranger® 250 Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
Current Voltage Load
(Amps) Volts (Watts)
14 AWG
12 AWG
10 AWG
8 AWG
6 AWG
4 AWG
15
20
15
20
40
120
120
240
240
240
1800
2400
3600
4800
9500
30
60
(9)
40
(12)
(9)
75
(23)
(15)
(46)
(30)
(15)
125
(38)
(27)
(69)
(53)
(27)
175
(53)
(42)
(107)
(84)
(46)
300
(91)
(69)
30
75
60
50
150
100
50
88
225
175
90
138
350
275
150
225
600
450
225
(18)
(23)
(18)
(183)
(137)
(69)
Conductor size is based on maximum 2.0% voltage drop.
RANGER® 250
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C-1
C-1
ACCESSORIES
K1690-1 GFCI RECEPTACLE KIT - Includes one UL
approved 120V ground fault circuit interrupter duplex
type receptacle with cover and installation instruc-
tions. 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 the 20 Amps. Two kits are
required.
RECOMMENDED OPTIONAL
EQUIPMENT
K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR
SMALL WELDERS - For road, off-road and in-plant
and yard towing. (For highway use, consult applicable
federal, state and local laws regarding requirements
for brakes, lights, fenders, etc.). Order:
K957-1 Trailer
K958-1 Ball Hitch
K802N POWER PLUG KIT
K958-2 Lunette Eye Hitch
K959-2 Fender & Light Kit
K965-1 Cable Storage Rack
Provides four 120 volt plugs rated at 20 amps each
and one dual voltage, full KVA plug rated at 120/240
volts, 50 amps.
K802R POWER PLUG KIT
K1737-1 FOUR WHEEL ALL-TERRAIN UNDER-
CARRIAGE - For moving by hand at construction
sites. Heavy duty puncture resistant pneumatic tires.
Provides four 120 volt plugs rated at 15 amps each
and one dual voltage, full KVA plug rated at 120/240
volts, 50 amps.
K1770-1 UNDERCARRIAGE (FACTORY)
For moving by hand on a smooth surface. Heavy duty
puncture resistant pneumatic tires and front caster.
One or two gas cylinders can be mounted on the rear
of the undercarriage with the installation of K1745-1
Cylinder Holder(s).
T12153-9 50 AMP, 120/240V POWER PLUG
K1816-1 FULL KVA ADAPTER KIT
Plugs into the 120/240V NEMA 14-50R receptacle on
the case front (which accepts 4-prong plugs) and con-
verts it to a NEMA 6-50R receptacle, (which accepts
3-prong plugs.)
K1739-1 CABLE CARRIER KIT - For use on K1737-1
and K1770-1 Undercarriages.
TIG Welding
K1783-9 TIG Torch PTA-26V (25ft.)
K963-3 Hand Amptrol
K870 Foot Amptrol
K1745-1 WELDING GAS CYLINDER LPG TANK
HOLDER - For use on K1770-1 Undercarriage. One
or two may be installed on an undercarriage.
KP509 Magnum Parts Kit
K1788-1 ROLL CAGE - Gives added damage protection.
Spool Gun
K487-25 Magnum Spool Gun
K488 Magnum Control Module
K886-2 CANVAS COVER - Protects machine when not
in use.
K691-10 Input Cable
K1898-1 SPARK ARRESTER - Mounts inside
exhaust pipe.
K704 ACCESSORY SET - Includes 35 ft. (10m) of
electrode cable and 30 ft. (9.1m) of work cable, head-
shield, work clamp electrode holder. Cables are rated
at 400 amps, 100% duty cycle.
K857 25 ft (7.5m) or K857-1 100 ft. (30.4m) REMOTE CON-
TROL - 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.
RANGER® 250
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D-1
D-1
MAINTENANCE
KOHLER ENGINE
SAFETY PRECAUTIONS
FREQUENCY
MAINTENANCE REQUIRED
WARNING
• Fill fuel tank.
Daily or Before
• Check oil level.
Starting Engine
• Have qualified personnel do all maintenance
and troubleshooting work.
• Check air cleaner for dirty, loose, or dam-
aged parts.
• Turn the engine off before working inside the
machine or servicing the engine.
• Check air intake and cooling areas, clean
as necessary.
• First Oil Change
5 Hours
• Remove guards only when necessary to
perform maintenance and replace them when
the maintenance requiring their removal is
complete. If guards are missing from the
machine, obtain replacements from a Lincoln
Distributor. (See Operating Manual Parts List.)
Every 25 Hours
• Service air pre-cleaner..
(1)
• Change engine oil.
Every 100 Hours
Every 100 Hours
Every 100 Hours
• Replace fuel filter element.
(1)
• Clean or replace air filter element.
• Spark Arrester
Every 100 Hours
Every 200 Hours
Every 200 Hours
(1)
• Replace oil filter.
Read the Safety Precautions in the front of this
manual and in the Engine Ownerʼs Manual before
working on this machine.
• Check spark plug and gap
• Check fuel lines and clamps.
(1) Service more frequently when used in dusty areas and/or at high ambient
temperatures.
Keep all equipment safety guards, covers, and
devices in position and in good repair. Keep
hands, hair, clothing, and tools away from the
gears, fans, and all other moving parts when
starting, operating, or repairing the equipment.
------------------------------------------------------------------------
Routine Maintenance
SUBARU ROBIN ENGINE
FREQUENCY
MAINTENANCE REQUIRED
• Fill fuel tank.
Daily or Before
• Check oil level.
Starting Engine
•
Check air cleaner for dirty, loose, or damaged parts.
• Check air intake and cooling areas, clean as necessary.
• CInhsecpkefocrtfufeol lrealokaogesefromhafuredl swysaterme. aRenpdairrief nteigedhetde. n.
•
At the end of each dayʼs use, refill the fuel tank to
minimize 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.
After initial 20 Hours
Every 50 Hours
Every 100 Hours
•Change oil and oil filter.
• Clean spark plugs.
• Clean outer element of air cleaner.
(1)
• Change engine oil.
• Clean fuel strainer.
(1)
• Replace air cleaner assembly.
Every 200 Hours
• Inspect, clean, and re-gap Spark Plugs.
(1)
• Change engine oil filter.
• Clean Carburetor.
• Clean cylinder head.
Every 500 Hours
Every 1000 Hours
• Adjust engine valve clearance.
• Replace spark plugs.
• Replace fuel lines and filter.
(1) Service more frequently when used in dusty areas and/or at high ambient
temperatures.
ENGINE MAINTENANCE COMPONENTS
ITEM
MAKE AND PART NUMBER
KOHLER CH23S ENGINE
SUBARU ROBIN EH65 ENGINE
Code Number 11422 and above
Code Numbers 11401 and above
Oil Filter
Kohler 12 050 01, Fram PH8172
Subaru Robin 248-65801-00, Fram PH4967
Subaru Robin 263-32610-A1
N/A
Air Filter Element
Air Filter Pre-Cleaner
Fuel Filter
Kohler 47 083 03, Fram CA79
Kohler 24 083 02
Kohler 24 050 13
Subaru Robin 011-00600-20
Subaru Robin X65-01407-30, NGK BPR4EY
BCI Group 58 (435 CCA)
Spark Plug
Champion RC12YC (.030" Gap)
Battery
BCI Group 58 (435 CCA)
RANGER® 250
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D-2
D-2
MAINTENANCE
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.
ENGINE OIL CHANGE
Drain the oil while the engine is warm to assure rapid and
complete draining.
• Remove the oil filler cap and dipstick. Remove the yel-
low 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.
• Close the drain valve by pushing in and twisting clock-
wise. Replace the yellow cap.
• Refill to the upper limit mark on the dipstick with the rec-
ommended oil. Tighten the oil filler cap securely.
AIR CLEANER SERVICE
A dirty air cleaner will restrict air flow to the carbure-
tor. To prevent carburetor malfunction, service the air
cleaner regularly. Service more frequently when
operating the engine in extremely dusty areas.
ENGINE OIL REFILL CAPACITIES
Without oil filter replacement:
• 1.7qt. (1.6 liter)-Kohler
• 1.5 qt. (1.4 liter)-Subaru Robin
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 qt. (1.9 liter)-Kohler
• 1.65 qt. (1.6 liter)-Subaru Robin
Use 4-stroke motor oil that meets or exceeds the require-
ments for API service classification SG or SH. Always
check the API SERVICE label on the oil container 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-tempera-
ture use, -5° F to 104° F (-20° C to 40° C). For the
Subaru Robin engine, it is recommended that SAE 30 oil
be used above 82° F (27° C).
-----------------------------------------------------------------------
AIR PRE-CLEANER SERVICE
1. Loosen the cover retaining knob and remove the
cover.
See Engine Ownerʼs Manual for more specific information
on oil viscosity recommendations.
Wash your hands with soap and water after handling
used oil.
2. Remove the pre-cleaner from the paper element.
3. Wash the pre-cleaner in warm water with detergent.
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.
Please dispose of used motor oil in a manner that is com-
patible with the environment. We suggest you take it in a
sealed container to your local service station or recycling
center for reclamation. Do not throw it in the trash, pour it
on the ground or down a drain.
4. Saturate the pre-cleaner with new engine oil.
Squeeze out all excess oil.
OIL FILTER CHANGE
1. Drain the engine oil.
5. Reinstall the pre-cleaner over the paper element.
2. Remove the oil filter, and drain the oil into a suitable
container. Discard the used oil filter.
6. Reinstall the air cleaner cover. Secure 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
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D-3
D-3
MAINTENANCE
5. Measure the plug gap with a feeler gauge. Correct
as necessary by bending the side electrode.
AIR FILTER PAPER ELEMENT
1. Loosen the cover retaining knob and remove the
cover.
6. Check that the spark plug washer is in good condi-
tion and thread the spark plug in by hand to prevent
cross-threading.
2. Remove the pre-cleaner from the paper element.
3. Remove the element cover nut, element cover, and
paper element.
7. After the spark plug is seated, tighten with a spark
plug wrench to compress the washer. (See proper
spark plug torque which is specified below).
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 engine
.025 in. (0.64 mm)-Robin-Subaru engine
Spark Plug Torque:
5. When servicing the air cleaner, check the air clean-
er base. Make sure it is secured and not bent or
damaged. Also check the element cover for dam-
aged or improper fit. Replace all damaged air
cleaner components.
20 ft. Lb. (27 N-m)-Kohler engine
11 ft. Lb. (14 N-m)-Robin-Subaru engine
CAUTION
NOTE: Before air cleaner is reassembled make sure
rubber seal is in position around stud. Inspect, making
sure it is not damaged and seals with the element
cover.
The spark plug must be securely tightened. An
improperly tightened spark plug can become very
hot and may cause engine damage. 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 cover with the cover retaining knob.
------------------------------------------------------------------------
SPARK PLUG
To ensure proper engine operation, the spark plug
must be properly gapped and free of deposits.
WARNING
NOTE: Before removing spark plug, the muffler
becomes very hot during operation and remains
hot for a while after stopping the engine. Be care-
ful not to touch the muffler while it is hot.
------------------------------------------------------------------------
SPARK PLUG SERVICE
To ensure proper engine operation, the spark plug
must be properly gapped and free of deposits.
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 plug.
4. Visually inspect the spark plug. Discard them if the
insulator is cracked or chipped. Clean the spark
plug with a wire brush if it is to be reused.
RANGER® 250
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D-4
D-4
MAINTENANCE
CLEANING THE BATTERY
FUEL FILTER
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 (0.12 kg)
of baking soda and 1 quart (0.1 liter) of water. Be sure
the battery vent plugs (if equipped) are tight so that
none of the solution enters the cells.
1. Check the fuel filter for water accumulation or sedi-
ment.
2. Replace the fuel filter if it is found with excessive
water accumulation or sediment.
ENGINE ADJUSTMENT
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.
Keep the battery clean and dry. Moisture accumula-
tion on the battery can lead to more rapid discharge
and early battery failure.
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.
CHECKING THE ELECTROLYTE LEVEL
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.
Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.
BATTERY MAINTENANCE
CHARGING THE BATTERY
To access the battery, Remove the 2 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 battery terminals.
When you charge, jump, replace, or otherwise con-
nect battery cables to the battery, be sure the polarity
is correct. Improper polarity can damage the charging
circuit. The RANGER® 250 positive (+) battery termi-
nal has a red terminal cover.
WARNING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes
away from battery.
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
battery cable first and the negative cable last. Failure
to do so can result in damage to the internal charger
components.
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and con-
nect to new battery last.
• CONNECTING A BATTERY CHARGER —
remove battery from welder by disconnecting
negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
Follow the instructions of the battery charger manu-
facturer for proper charger settings and charging time.
SERVICING OPTIONAL SPARK
ARRESTER
Clean every 100 hours.
WARNING
• USING A BOOSTER — connect positive lead to
battery first then connect negative lead to neg-
ative battery lead at engine foot.
BATTERY ACID can burn eyes and
skin.
MUFFLER MAY BE HOT
• ALLOW ENGINE TO COOL BEFORE INSTALLING
THE SPARK ARRESTER!
• Wear gloves and eye protection
and be careful when working near
battery.
• DO NOT OPERATE ENGINE WHILE INSTALLING
THE SPARK ARRESTER!
------------------------------------------------------------------------------------------
• Follow instructions printed on battery.
------------------------------------------------------------------------
RANGER® 250
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D-5
D-5
MAINTENANCE
WELDER / GENERATOR
MAINTENANCE
STORAGE: Store the RANGER® 250 in clean, dry
protected areas.
CLEANING: Blow out the generator and controls peri-
odically with low pressure air. Do this at least once a
week in particularly dirty areas.
BRUSH REMOVAL AND REPLACEMENT: Itʼs nor-
mal for the brushes and slip rings to wear and darken
slightly. Inspect the brushes when a generator over-
haul is necessary.
CAUTION
• Do not attempt to polish slip rings while the
engine is running.
WARNING
• Service and Repair should only be performed by
Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equip-
ment may result in danger to the technician and
machine operator and will invalidate your factory
warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and pre-
cautions.
------------------------------------------------------------------------
RANGER® 250
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E-1
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP-
TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
RANGER® 250
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE
RECOMMENDED
(SYMPTOMS)
CAUSE
COURSE OF ACTION
Major Physical or Electrical 1. If all recommended possible
Damage is Evident.
areas of misadjustment have
been checked and the problem
persists,Contact your local
Lincoln Authorized Field
Service Facility.
Engine will not "crank".
1. Battery is low.
2. Loose battery cable connections.
3. Faulty engine starter motor.
4. “Battery Circuit” circuit breaker is
tripped.
Engine will "crank" but not start.
1. Out of fuel.
2. Faulty fuel solenoid or faulty PC
board or ignition system.
3. Fuel pump not working.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
Engine shuts down shortly after 1. Low oil level.
starting.
2. Faulty oil pressure switch or
other engine component.
Battery does not stay charged.
1. Faulty battery.
2. Loose connections at battery or
alternator.
3. Faulty engine alternator or
charger module.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
RANGER® 250
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE
RECOMMENDED
(SYMPTOMS)
CAUSE
COURSE OF ACTION
Engine will not idle down to low 1. Idler switch in High idle position.
speed.
2. External load on welder or auxil-
iary power.
3. Faulty PC board or idler sole-
noid.
Engine will not go to high idle when 1. Poor work lead connection to
attempting to weld.
work.
2. "Contactor" switch is in wrong
position.
3. Faulty PC board. Low idle speed
set to low.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
Engine will not go to high idle when 1. Auxiliary power load is less than
using auxiliary power.
100 watts.
2. Faulty PC board.
Engine does not develop full power. 1. Fuel filter clogged.
2. Fuel lift pump not working.
3. Air filter clogged.
4. Fouled spark plugs.
5. Valves out of adjustment.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
RANGER® 250
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E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE
RECOMMENDED
(SYMPTOMS)
CAUSE
COURSE OF ACTION
No welding power output.
1. Poor work lead connection to
work.
2. "Weld Terminals" switch in
wrong position.
3. Faulty PC board or welder alter-
nator.
Welder has output but no control.
1. Poor remote / control cable con-
nection to 6 pin or 14 pin
Amphenol connector.
2. Faulty remote cable or faulty
wire feeder or wire feeder cable.
3. Faulty control potentiometer or
PC board.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service
Facility.
Wire feeder does not work when 1. Wire Feeder Power circuit
control cable is connected to 14 pin
Connector.
breaker open.
2. Faulty control cable.
3. Faulty wire feeder.
No auxiliary power.
1. Open circuit breakers.
2. Faulty connections to auxiliary
receptacles.
3. GFCI tripped (if installed).
4. Brushes worn or not on contact
with slip rings.
5. Rotor winding not receiving
flashing current from PC board.
6. Rotor winding open.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
RANGER® 250
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E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE
RECOMMENDED
(SYMPTOMS)
CAUSE
COURSE OF ACTION
The welding arc is “cold.” The
welding arc is not stable or is not
satisfactory. the engine runs nor-
mally. The auxiliary power is nor-
mal.
1. Make sure the MODE selector
switch is in the correct position
for the process being used. (For
example, CV-WIRE, PIPE, CC-
STICK.)
2. Make sure the electrode (wire,
gas, voltage, current etc.) is cor-
rect for the process being used.
3. Check for loose or faulty con-
nections at the weld output ter-
minals and welding cable con-
nections.
4. The welding cables may be too
long or coiled, causing an exces-
sive voltage drop.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
RANGER® 250
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F-1
F-1
DIAGRAMS
RANGER® 250
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F-2
F-2
DIAGRAMS
RANGER® 250
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F-3
F-3
DIAGRAMS
RANGER® 250
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F-4
F-4
DIAGRAMS
RANGER® 250
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F-5
F-5
DIAGRAMS
RANGER® 250
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F-6
F-6
DIAGRAMS
RANGER® 250
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F-7
F-7
DIAGRAMS
RANGER® 250
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F-8
F-8
DIAGRAMS
RANGER® 250
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F-9
F-9
DIAGRAMS
RANGER® 250
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F-10
F-10
DIAGRAMS
RANGER® 250
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F-11
F-11
DIAGRAMS
RANGER® 250
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F-12
F-12
DIMENSION PRINT
RANGER® 250
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● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● Keep flammable materials away.
● Wear eye, ear and body protection.
WARNING
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
cuerpo.
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
Spanish
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● Débranchez le courant avant
l’entretien.
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ATTENTION
German
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
● Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• 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
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