Lincoln Electric Welding System IM919 User Manual

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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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