Lincoln Electric IM10052 User Manual

Operator’s Manual

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RANGER®250 GXT (AU)Model

For use with machines having Code Numbers:

11689, 11741, 11796, 11803,
12099, 12194, 12205

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10052-E | Issue D ate Sept-13

© Lincoln Global, Inc. All Rights Reserved.

Register your machine:

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

Need Help? Call 1.888.935.3877

to talk to a Service Representative

Hours of Operation:

8:00 AM to 6:00 PM (ET) Mon. thru Fri.

After hours?

Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.

For Service outside the USA:

Email: [e-mail]

THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.

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.

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 thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT. And, most importantly, think before you

act and be careful.

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.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to
stay a reasonable distance away
from the arc.

READ and obey the Material Safety

Data Sheet (MSDS) and the warning
label that appears on all containers
of welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to keep
the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your

face.

If you de velop unusual symptoms, see your supervisor. Perhaps the
welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate
(See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly
cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly
toxic fumes or gases.

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.

Gasoline Engines

The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY. PACE­MAKER WEARERS SHOULD CONSULT WITH THEIR
DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional
safety information, it is strongly recommended that you purchase a
copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the
American Welding Society, P.O. Box 351040, Miami, Florida 33135 or
CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety”
booklet E205 is available from the Lincoln Electric Company, 22801
St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

SAFETY

1.d. Keep all equipment safety guards, covers and
devices in position and in good repair.Keep
hands, hair, clothing and tools away from
V-belts, gears, fans and all other moving parts
when starting, operating or repairing
equipment.

1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.

1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is

hot.

ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS

2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and welding
machines

FOR ENGINE POWERED
EQUIPMENT.

1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.

2.b. EMF fields may interfere with some pacemakers, and welders
having a pacemaker should consult their physician before
welding.

2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos­sible to the area being welded.

2.d.5. Do not work next to welding power source.

3

SAFETY

ELECTRIC SHOCK
CAN KILL.

3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin
or wet clothing. Wear dry, hole-free gloves to insulate hands.

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.

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:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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.

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

two can be the total of the open circuit voltage of both
welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

between the

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.

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.

FUMES AND GASES
CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough 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 within applicable OSHA PEL and
ACGIH TLV limits 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.

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 specific
welding procedure and application 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.

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 products.

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your employer’s
safety practices. MSDS forms are available from your welding
distributor or from the manufacturer.

5.f. Also see item 1.b.

4

cause

SAFETY

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember that welding
sparks and hot materials from welding can easily go through
small cracks and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

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.

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.

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).

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.

6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER MAY EXPLODE IF
DAMAGED.

7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.

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.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

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.

FOR ELECTRICALLY
POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.

8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.

6.I. Read and follow 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.

6.j. Do not use a welding power source for pipe thawing.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety
Interactive Web Guide
for mobile devices

5

vi

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions ........................................................................................................A-2

Machine Grounding.......................................................................................................A-2

Spark Arrester ...............................................................................................................A-2

Towing...........................................................................................................................A-2

Vehicle Mounting...........................................................................................................A-3

Pre-Operation Engine Service..............................................................................................A-3

Fuel, Oil, Battery Connections ......................................................................................A-3

Welding Cable Connections..........................................................................................A-4

Angle of Operation ........................................................................................................A-4

Lifting, Additional Safety Precautions............................................................................A-4

High Altitude Operation .................................................................................................A-4

Muffler Outlet Pipe ........................................................................................................A-4

Location and Ventilation................................................................................................A-5

Stacking ........................................................................................................................A-5

Connection of Wire Feeders .........................................................................................A-5

Connection of Tig Module .............................................................................................A-5

Additional Safety Precautions .......................................................................................A-5

Welding Operation Output, Auxiliary Power Receptacles, and Plugs .................................A-6

Motor Starting and Extension Cord Length Table ................................................................A-6

Electrical Device Used with the Ranger 250 GXT (AU) .......................................................A-7

Auxiliary Power While Welding, Standby Power Connections ............................................A-8

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

General Description..............................................................................................................B-1

Welder Controls Function and Operation .............................................................................B-1

Polarity, Range and Control Switch......................................................................................B-2

Start in/Shutdown Instructions.....................................................................................................B-3

Starting the Engine........................................................................................................B-3

Safety Precautions ........................................................................................................B-3

Stopping the Engine......................................................................................................B-3

Break-In Period .............................................................................................................B-3

Welding Process ..................................................................................................................B-4

Stick (Constant Current) Welding..................................................................................B-4

TIG (Constant Current) Welding ..................................................................................B-4

Wire Feed Welding Processes (Constant Voltage)......................................................B-4

Arc Gouging ..................................................................................................................B-4

Summary of Welding Processes ...................................................................................B-5

________________________________________________________________________________

Accessories ........................................................................................................Section C

Optional Equipment...............................................................................................C-1

Recommended Equipment....................................................................................C-2

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Engine Maintenance ..........................................................................D-1,D2

Engine Adjustments...............................................................................................D-3

Slip Rings ..............................................................................................................D-3

Battery Maintenance .......................................................................................D-3

Engine Maintenance Parts..............................................................................D-3

________________________________________________________________________

Troubleshooting..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide...................................................................................E-2, E-3

________________________________________________________________________

Wiring Diagrams, Connection Diagrams & Dimension Print.......................Section F

________________________________________________________________________

Parts List.................................................................................................... P-645 Series

________________________________________________________________________

vi

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - Ranger® 250 GXT (AU) ( K2923-1)

INPUT - GASOLINE ENGINE

Make/Model

Kohler

CH23S,

CH680

CH730

Description

2 cylinder

4 Cycle

Air-Cooled

Gasoline

Engine.

Aluminum Alloy

with Cast Iron

Liners,

Electronic

Ignition

RATED OUTPUT @ 104°F (40°C)- WELDER

RATED OUTPUT @ 104°F (40°C)- GENERATOR

Horsepower

23 HP @

3600 RPM

AC Constant Current 250A / 25V / 100%
DC Constant Current 250A / 25V / 100%
DC Constant Voltage 250A / 25V / 100%

Operating

Speed (RPM)

High Idle 3700

Full Load 3500

Low Idle 2200

Welding Output

Auxiliary Power

Displacement

cu. in.

(cu.cm.)

41.1(674)

44.2(724)

1

Starting

System

12VDC
Battery

Electric Start

Group 58

Battery
(435 cold
Cranking

Amps)

A-1

Capacities

Fuel:

12 Gal (45.4 L)

Lubricating Oil:

2.0 Qts. (1.9 L)

7,200 Watts Continuous, 60 Hz AC

240 Volts

RECEPTACLES AND CIRCUIT BREAKERS

RECEPTACLES

(2) 240VAC Receptacles

AUXILIARY POWER CIRCUIT BREAKER

Two 15AMP for Two Receptacles

BATTERY CHARGING CIRCUIT BREAKER

20AMP for Engine Battery

Charging Circuit

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

Codes 11803 and below

30.00** in. 21.50 in 42.25 in.

762.0 mm 546.0 mm 1073.0 mm

** Top of enclosure, add 6.00”(152mm) for exhaust.

567 lbs. (257kg.)

Code 12099

574 lbs. (260kg.)

ENGINE COMPONENTS

LUBRICATION VALVE LIFTERS FUEL SYSTEM GOVERNOR

Full Pressure Hydraulic Electric fuel lift pump. Mechanical Governor

with Full Flow Filter

5% Regulation

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Low noise Muffler: Top outlet Shutdown on low oil

Dual Element Automatic Idler can be rotated. Made from pressure.

long life, aluminized steel.

1

Output rating in watts is equivalent to volt - amperes at unity factor.Output voltage is within +/-10% at all loads up to rated capacity.

When welding available auxiliary power will be reduced.

RANGER® 250 GXT (AU)

A-2

INSTALLATION

A-2

SAFETY PRECAUTIONS

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.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or
guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

When this welder is mounted on a truck or trailer, itʼs
frame must be electrically bonded to the metal frame
of the vehicle. Use a #8 or larger copper wire connect­ed between the machine grounding stud and the
frame of the vehicle.

Where this engine driven welder is connected to
premises wiring such as that in your home or shop, itʼs
frame must be connected to the system earth ground.
See further connection instructions in the section enti­tled “Standby Power Connections”, as well as the arti­cle on grounding in the latest National Electrical Code
and the local code.

In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into
the ground for at least ten feet and having no insulat­ed joints, or to the metal framework of a building
which has been effectively grounded. The 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.

SPARK ARRESTER

See additional warning information at

front of this operatorʼs manual.

-----------------------------------------------------------

MACHINE GROUNDING

Because this portable engine driven welder or genera­tor creates itʼs own power, it is not necessary to con­nect itʼs frame to an earth ground, unless the machine
is connected to premises wiring (your home, shop,
etc.).

WARNING

To prevent dangerous electric shock, other equip­ment to which this engine driven welder supplies
power must:

• be grounded to the frame of the welder using a
grounded type plug, or be double insulated.

Do not ground the machine to a pipe that carries
explosive or combustible material.

------------------------------------------------------------------------

Some federal, state, or local laws may require that
gasoline 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 qualify as a spark arrester. When required by local
regulations, the K1898-1 spark arrester must be
installed and properly maintained.

CAUTION

An incorrect arrester may lead to damage to the
engine or adversely affect performance.

------------------------------------------------------------------------

TOWING

The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle
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:

1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.

(1)

is

2. Proper support of, and attachment to, the base of

the welding equipment so there will be no undue
stress to the framework.

RANGER® 250 GXT (AU)

A-3

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.

4. Typical conditions of use, i.e., travel speed; rough-

ness of surface on which the trailer will be operated;
environmental conditions.

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

INSTALLATION

(1)

WARNING

Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.

• Only transport this Equipment on serviceable
vehicles which are rated and designed for such
loads.

• Distribute, balance and secure loads so vehicle
is stable under conditions of use.

• Do not exceed maximum rated loads for compo­nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of
vehicle.

• Follow vehicle manufacturerʼs instructions.

------------------------------------------------------------------------

PRE-OPERATION SERVICE

CAUTION

READ the engine operating and maintenance
instructions supplied with this machine.

A-3

FUEL

Fill the fuel tank with clean, fresh, lead-free gasoline.
Observe fuel gauge while filling to prevent overfilling.

Stop fueling once the fuel gauge reads full. Do not top
off tank. Be sure to leave filler neck empty to allow
room for expansion.

FULL

WARNING

• Damage to the fuel tank may cause
fire or explosion. Do not
in the RANGER
weld to the RANGER

-----------------------------------------------------------------------

OIL

LUBRICATION  SYSTEM  CAPACITY

Kohler CH23S, CH680, CH730 - 2.0 Quarts (1.9 Liters)

The RANGER
crankcase filled with 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. Make cer­tain that the oil filler cap is tightened securely. Refer to
the engine Ownerʼs Manual for specific oil recommen­dations.

base.

(INCLUDING  FILTER)

®

GXT (AU) is shipped with the engine

®

GXT (AU) base or

drill holes

®

GXT (AU)

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away
from tank.

• Do not leave unattended while
fueling.

• Wipe up spilled fuel and allow

GASOLINE

can cause fire
or explosion.

fumes to clear before starting
engine.

• Do not overfill tank, fuel expan­sion may cause overflow.

GASOLINE FUEL ONLY

------------------------------------------------------------------------

RANGER® 250 GXT (AU)

CAUTION

BATTERY CONNECTIONS

Use caution as the electrolyte is a strong acid that
can burn skin and damage eyes.

------------------------------------------------------------------------

This welder is shipped with the negative battery cable
disconnected. Make sure that the Engine Switch is in
the “STOP” position and attach the disconnected
cable securely to the negative battery terminal before
attempting to operate the machine. If the battery is
discharged and does not have enough power to start
the engine, see the battery charging instructions in the
Battery section.

NOTE: This machine is furnished with a wet charged
battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the bat­tery with the correct polarity.

A-4

INSTALLATION

WELDING OUTPUT CABLES

With the engine off, connect the electrode and work
cables to the studs provided. These connections
should be checked periodically and tightened if neces­sary. Loose connections will result in overheating of
the output studs.

When welding at a considerable distance from the
welder, be sure you use ample size welding cables.
Listed below are copper cable sizes recommended for
the rated current and duty cycle. Lengths stipulated
are the distance from the welder to work and back to
the welder again. Cable sizes are increased for
greater lengths primarily for the purpose of minimizing
cable voltage drop.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

250 Amps

100% Duty Cycle

0-100 Ft. (0-31m)

100-150 Ft. (31-46m)

150-200 Ft. (46-61m)

1 AWG

1 AWG

1/0 AWG

ANGLE OF OPERATION

Internal combustion engines are designed to run in a
level condition which is where the optimum perfor­mance is achieved. The maximum angle of operation
for the engine is 15 degrees from horizontal in any
direction. If the engine is to be operated at an angle,
provisions must be made for checking and maintain­ing the oil at the normal (FULL) oil capacity in the
crankcase in a level condition.

When operating at an angle, the effective fuel capacity
will be slightly less than the specified 12 Gal. (45 L).

A-4

ADDITIONAL SAFETY PRECAUTION

WARNING

• Lift only with equipment of
adequate lifting capacity.

• Be sure machine is stable
when lifting.

• Do not lift this machine using
lift bail if it is equipped with a
heavy accessory such as trail­er or gas cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

------------------------------------------------------------------------

HIGH ALTITUDE OPERATION

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.

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.

------------------------------------------------------------------------

MUFFLER OUTLET PIPE

LIFTING

The Ranger® 250 GXT (AU) weighs approximately
646lbs.(293kg) with a full tank of gasoline. A lift bail is
mounted to the machine and should always be used
when lifting the machine.

RANGER® 250 GXT (AU)

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.

A-5

INSTALLATION

LOCATION / VENTILATION

The welder should be located to provide an unrestrict­ed flow of clean, cool air to the cooling air inlets and to
avoid heated air coming out of the welder recirculating
back to the cooling air inlet. Also, locate the welder so
that engine exhaust fumes are properly vented to an
outside area.

STACKING

Ranger® 250 GXT (AU) machines cannot be stacked.

CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS

WARNING

Shut off welder before making any electrical
connections.

-----------------------------------------------------------------------

WIRE FEED (CONSTANT VOLTAGE)
CONNECTION OF LN-15 ACROSS-THE-ARC WIRE
FEEDER

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.

• Shut the welder off.
Connect the electrode cable from the LN-15 to

•

“ELECTRODE” terminal of the welder. Connect

the
the work cable to the “TO WORK” terminal of the
welder.

• Set the Polarity switch to the desired polarity, either
DC (-) or DC (+).

• 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 “RANGE” switch to the “WIRE FEED-CV”
position

• Place the Engine switch in the “Auto Idle” position
when welding with MIG wire instead of self-shielded
core wire, weld starts can be improved by setting
the idle mode to “HIGH”.

• Adjust the wire feed speed at the LN-15 and adjust
the welding voltage with the output “CONTROL” at
the welder.
when welding with MIG wire instead of self-shielded
core wire, weld starts can be improved by setting
the idle mode to “HIGH”

Note: LN-15 Control Cable model will not work with

Output “CONTROL” must be set above 3

.

the Ranger® 250 GXT (AU).

A-5

• Position the “RANGE” switch to the “WIRE FEED
CV” position.

• Attach the single lead from the LN-25 control box
to the work using the spring clip on the end of the
lead - it carries no welding current.

• Place the engine switch in the “AUTO IDLE” posi­tion.

• When welding with MIG wire instead of self­shielded core wire, weld starts can be improved
by setting the idle mode to “HIGH”

• Adjust wire feed speed at the LN-25 and adjust
the welding voltage with the output “CONTROL”
at the welder.

NOTE: The welding electrode is energized at all
times, unless an LN-25 with built-in contactor is used.
If the output “CONTROL” is set below “3”, the LN-25
contactor may not pull in.

CONNECTION OF THE LN-25 TO THE

250 GXT (AU)

• Shut the welder off.
Connect the electrode cable from the LN-25 to

•

“ELECTRODE” terminal of the welder.

the
Connect the work cable to the “TO WORK” termi­nal of the welder.

• Position the welder “Polarity” switch to the desired
polarity, either DC (-) or DC (+).

CONNECTION OF K930-2 TIG MODULE TO THE
RANGER® 250 GXT (AU).

The TIG Module is an accessory that provides high
frequency and shielding gas control for AC and DC
GTAW (TIG) welding. See IM528 supplied with the
TIG Module for installation instructions.

Note: The TIG Module does not require the use of a
high frequency bypass capacitor. However, if the
Ranger® 250 GXT (AU) is used with any other high
frequency equipment, the bypass capacitor must be
installed, order kit T12246.

.

RANGER®

INSTRUCTIONS

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the roof and case
sides in place as this provides maximum protection
from moving parts and assures proper cooling air flow.

Read and understand all Safety Precautions before
operating this machine. Always follow these and any
other safety procedures included in this manual and in
the Engine Ownerʼs Manual.

RANGER® 250 GXT (AU)

A-6

INSTALLATION

WELDER OPERATION

WELDER OUTPUT

• Maximum Open Circuit Voltage at 3700 RPM is
80 Volts RMS.

• 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. Duty
Cycle for the Ranger® 250 GXT (AU) is 100%.

Ranger® 250 GXT (AU)

Constant Current 250 Amps AC @ 25 Volts

250 Amps DC @ 25 Volts

Constant Voltage 250 Amps DC @ 25 Volts

AUXILIARY POWER

The auxiliary power capacity of the Ranger® 250 GXT
(AU) is 7.2KW of 60Hz single phase power protected
by an RCD (Residual Current Device) and 2 single
phase 15 amp circuit breakers. The auxiliary power
capacity in watts equivalent to volt-amperes at unity
power factor.
This model has:

1 Residual Current Device (RCD) protection (30mA).

2 x 1 phase 15 amp Circuit Breakers.
2 x 1 phase 240 volt 15 amp per outlet.

A-6

MOTOR STARTING

Most 1.5 hp AC single phase motors can be started if
there is no load on the motor or other load connected
to the machine, since the full load current rating of a

1.5 hp motor is approximately 10 amperes for 240 volt
motors. The motor may be run at full load when
plugged into only one side of the duplex receptacle.
Larger motors through 2 hp can be run provided the
receptacle rating as previously stated is not exceeded.

Note: The single-phase outlets are from different

phases and cannot be paralleled.

The auxiliary power receptacles should only be used
with three grounded type plugs or approved double
insulated tools. The current rating of any plug used
with the system must be at least equal to the current
capacity of the associated receptacle.

CAUTION

Do not connect any plugs that connect to the
power receptacles in parallel.

------------------------------------------------------------------------

Start the engine and set the “IDLER” control switch to
the desired operating mode. Set the “CONTROL” to

10. Voltage is now correct at the receptacles for auxil­iary power.

Ranger® 250 GXT (AU) Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

Current

(Amps)

15

Voltage

Volts

240

Load

(Watts)

3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

Maximum Allowable Cord Length in ft. (m) for Conductor Size

Conductor size is based on maximum 2.0% voltage drop.

RANGER® 250 GXT (AU)

A-7

ELECTRICAL DEVICE USE WITH THE Ranger® 250 GXT (AU).

Type Common Electrical Devices Possible Concerns

Resistive Heaters, toasters, incandescent NONE

light bulbs, electric range, hot
pan, skillet, coffee maker.

Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage

appliances with electrical control. regulation can cause the capaci-

Inductive Single-phase induction motors, These devices require large

drills, well pumps, grinders, small current inrush for starting.
refrigerators, weed and hedge Some synchronous motors may
trimmers be frequency sensitive to attain

INSTALLATION

TABLE lll

tative elements to fail. Surge
protection, transient protection,
and additional loading is recom­mended for 100% fail-safe oper-

ation. DO NOT RUN THESE

DEVICES WITHOUT ADDI­TIONAL RESISTIVE TYPE
LOADS.

maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.

A-7

Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-

complicated electrical equipment. er along with transient and

surge protection is required, and

liabilities still exist. DO NOT

USE THESE DEVICES WITH A
Ranger® 250 GXT (AU)

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected
to the Ranger® 250 GXT (AU).

RANGER® 250 GXT (AU)

A-8

INSTALLATION

AUXILIARY POWER WHILE WELDING

Simultaneous welding and power loads are permitted
by following Table I. The permissible currents shown
assume that current is being drawn from either recep­tacle of 240V supply. Also, the “Output Control” is set
at “10” for maximum auxiliary power.

TABLE I

SIMULTANEOUS WELDING AND POWER

Output Selector Permissible Power Permissible Auxiliary

Setting Watts (Unity Power Current in Amperes

Factor) 240V

Max. Stick or Wire

Feed Setting None 0

180 Stick Setting 5100 21

130 Stick Setting 7200 30

No Welding 7200 30

*

A-8

* Each receptacle is limited to 15 amps.

STANDBY POWER CONNECTIONS

The Ranger® 250 GXT (AU) is suitable for temporary,
standby or emergency power using the engine manu­facturerʼs recommended maintenance schedule.

Tha Ranger® 250 GXT (AU) can be permanently
installed as a standby power unit for 240 volt (60Hz).
Connections must be made by a licensed electrician
who can determine how the 240 VAC power can be
adapted to the particular installation and comply with
all applicable electrical codes. The following informa­tion can be used as a guide by the electrician for most
applications.

1. Install an isolation switch between the power com­pany meter and the premises disconnect. (The
Ranger® 250 GXT (AU) and the power company
supplies must not be connected together).

Switch rating must be the same or greater than the
customerʼs premises disconnect and service over cur­rent protection.

2. Take necessary steps to assure load is limited to
the capacity of the Ranger® 250 GXT (AU).
Loading above the rated output will reduce output
voltage below the allowable -10% of rated voltage
which may damage appliances or other motor-dri­ven equipment and may result in overheating of the
Ranger® 250 GXT (AU) engine.

RANGER® 250 GXT (AU)

B-1

OPERATION

SAFETY PRECAUTIONS

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.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

Do not touch electrically live parts or

•
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

• Always operate the welder with the hinged door
closed and the side panels in place.

B-1

WELDER CONTROLS - FUNCTION AND
OPERATION

ENGINE SWITCH

The engine switch is used to Start the Engine, Select
High Idle or Auto Idle while the engine is running, and
stop the Engine.

When placed in the “OFF” position, the ignition
circuit is de-energized to shut down the engine.

When held in the “START” position, the engine
starter motor is energized.

When in “HIGH IDLE” ( ) position, the engine will
run continuously at high idle.

• Read carefully the Safety Precautions page
before operating this machine. Always follow
these and any other safety procedures included
in this manual and in the Engine Instruction
Manual.

------------------------------------------------------------------------

GENERAL DESCRIPTION

The Ranger® 250 GXT (AU) is a twin-cylinder, gaso­line driven, multiprocess arc welder and AC power
generator. It is built in a heavy gauge steel case for
durability on the job site.

Codes 11796 and above meet EPA evaporative emis­sion requirements.

When in “AUTO IDLE” ( / ) position, the
engine will run continuously and the idler operates as
follows:

• Welding

When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
speed.

After welding ceases (and no auxiliary power is
being drawn), the engine will return to low idle
after approximately 10 to 14 seconds.

• Auxiliary Power

With the engine running at low idle and auxiliary
power for lights or tools is drawn (approximately
100-150 watts or greater) from the receptacles,
the engine will accelerate to high speed.  If no
power is being drawn from the receptacles (and
not welding) for 10-14 seconds, the idler reduces
the engine speed to low idle.

RANGER® 250 GXT (AU)

B-2

“ RANGE” SWITCH

OPERATION

6-PIN CONNECTOR

B-2

The “Range” switch is used to select one of four
amperage ranges with generous overlap for Stick/TIG
welding, or one Wire Feed welding range.

Process Range Setting Current Range

STICK/TIG
(constant current)
(4 range settings)

WIRE FEED

(constant voltage)

(2 range setting)

80 Max.
130 Max.
180 Max.
250 Max.

14 to 22V
18 to 28V

50 to 80 Amps

70 to 130 Amps
110 to 180 Amps
160 to 250 Amps

Up to 250 Amps

CAUTION

Never change the “RANGE” Switch setting while
welding. This will damage the switch.

------------------------------------------------------------------------

“ CONTROL” DIAL

Provides a fine welding current adjustment within the
Range Switch settings in the STICK mode and weld­ing voltage control with the Range switch set in the
wire feed mode.

For attaching optional remote control equipment.

LOCAL / REMOTE CONTROL SWITCH

(See Accessory Section For “K” numbers)

The toggle switch on the control panel labeled
"LOCAL" and "REMOTE" provides the option of con­trolling the welding output at the control panel or
remotely. Remote connections are made at the 6-pin
connector. For control at the control panel set the
switch in the "LOCAL" position.

For remote control set the switch in the "REMOTE"
position.

POLARITY SWITCH

Provides three selectable welding polarities:
AC, DC+ & DC-

CAUTION

Never change the Polarity switch setting while
welding. This will damage the switch.

------------------------------------------------------------------------

RANGER® 250 GXT (AU) APPROXIMATE FUEL CONSUMPTION

KOHLER

23 H.P. COMMAND CH23S, CH680

Low Idle - No Load

2400 RPM
High Idle - No Load
3700 RPM
AC CC Weld Output
250 Amps @ 25 Volts
DC CC Weld Output
250 Amps @ 25 Volts
DC CV Weld Output
250 Amps @ 25 Volts
Auxiliary Power
7200 Watts

.40 Gallons/Hour

(1.51 Liters/Hour)

.77 Gallons/Hour

(2.91 Liters/Hour)

1.27 Gallons/Hour
(4.82 Liters/Hour)

1.50 Gallons/Hour
(5.69 Liters/Hour)

1.41 Gallons/Hour
(5.33 Liters/Hour)

1.40 Gallons/Hour)
(5.29 Liters/Hour)

KOHLER

23 H.P. COMMAND CH730

.40 Gallons/Hour

(1.51 Liters/Hour)

.93 Gallons/Hour

(3.52 Liters/Hour)

1.50 Gallons/Hour
(5.68 Liters/Hour)

1.74 Gallons/Hour)
(6.59 Liters/Hour)

1.62 Gallons/Hour)

6.31( Liters/Hour)

1.89 Gallons/Hour)
(7.15 Liters/Hour)

RANGER® 250 GXT (AU)

B-3

OPERATION

B-3

STARTING/SHUTDOWN INSTRUCTIONS

STARTING THE ENGINE

WARNING

• Do not touch electrically live parts
of electrode with skin or wet
clothing.

• Keep flammable material away.

• Insulate yourself from work and
ground. Wear eye, ear, and body
protection.

• Keep your head out of the fumes.

• Use ventilation or exhaust to
remove fumes from breathing zone.

Be sure all Pre-Operation Maintenance has been per­formed. Also, read the Engine Ownerʼs Manual before
starting for the first time.

Remove all loads connected to the AC power recepta­cles. Use the choke control as follows:

KOHLER ENGINE - Always pull the choke control out
when starting the engine; cold, warm or hot.

Turn the engine switch to the “start” posi tion and
crank the engine until it starts. Release the switch as
soon as the engine starts, slowly return the choke
control to the full “in” position (choke open),
and turn the switch to the Auto Idle( / )
position. Do not turn the switch to the “start” position
while the engine is running because this will cause
damage to the ring gear and/or starter motor

STOPPING THE ENGINE

Remove all welding and auxiliary power loads and
allow engine to run at low idle speed for a few minutes
to cool the engine.

Stop the engine by placing the Engine switch in the

“OFF” position.

A fuel shut off valve is not required on the Ranger®
250 GXT (AU) because the fuel tank is mounted
below the engine.

BREAK-IN PERIOD

It is normal for any engine to use a greater amount of
oil until the break-in is accomplished. Check the oil
level twice a day during the break-in period (approxi­mately 50 running hours).

IMPORTANT: IN ORDER TO ACCOMPLISH THIS

BREAK-IN, THE UNIT SHOULD BE
SUBJECTED TO MODERATE
LOADS, WITHIN THE RATING OF
THE MACHINE. AVOID LONG IDLE
RUNNING PERIODS. REMOVE
LOADS AND ALLOW ENGINE TO
COOL BEFORE SHUTDOWN.

The engine manufacturerʼs recommendation for the
running time until the first oil change is as follows:

KOHLER

CH23S, CH680, CH730

5 HRS

The oil filter is to be changed at the second oil
change. Refer to the Engine Ownerʼs Manual for more
information.

After running at high engine speed for 10-14 seconds,
the engine will go to low idle.
Allow the engine to warm up by letting it run at low idle
for a few minutes.

RANGER® 250 GXT (AU)

B-4

OPERATION

WELDING PROCESS

For any electrodes the procedures should be kept within
the rating of the machine. For electrode information see

the appropriate Lincoln publication.

STICK (CONSTANT CURRENT) WELDING

Connect welding cables to the "TO WORK” and "ELEC­TRODE” studs. Start the engine. Set the "Polarity” switch
to the desired polarity. The “RANGE” switch markings
indicate the maximum current for that range as well as
the typical electrode size for that range. The “OUTPUT”
Control provides fine adjustment of the welding current
within the select range. For maximum output within a
selected range set the “OUTPUT” Control at 10. For min­imum output within a selected range set the “OUTPUT”
Control at 5. (“OUTPUT” Control settings below 5 may
reduce arc stability) For best overall welding perfor­mance set the “RANGE” Switch to the lowest setting and
the OUTPUT” Control near the maximum to achieve the
desired welding current.

B-4

SETTINGS FOR  1% THORIATED TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 80, 130, or 180 80 - 225 Amps
3/32 80 or 130 50 - 180 Amps
1/16 80 45 - 120 Amps

For AC TIG Welding, the maximum TIG Welding out­put currents on each range setting will be approxi­mately 50% higher than those marked on the name­plate. This is due to the special nature of the AC TIG
welding arc. Do not AC TIG weld on the 250 Amp set­ting. The output may exceed the rating of the
Ranger® 250 GXT (AU).

WIRE FEED WELDING PROCESSES
(CONSTANT VOLTAGE)

®

The Innershield
the Ranger® 250 GXT (AU) is NR
trode sizes and welding ranges that can be used with
the Ranger® 250 GXT (AU) are shown in the following
table:

electrode recommended for use with

®

-211-MP. The elec-

RANGE SETTING TYPICAL CURRENT RANGE

ELECTRODE SIZE

80 MAX.

130 MAX.

180 MAX.

250 MAX.

3/32

1/8

5/32

3/16

50 TO 80 AMPS

70 TO 130 AMPS

110 TO 180 AMPS

160 TO 250 AMPS

Diameter Wire Speed Approximate

The Ranger® 250 GXT (AU) is recommended for lim­ited “MIG” welding (GMAW - gas metal arc welding).

The Ranger® 250 GXT (AU) can be used with a broad
range of AC and DC stick electrodes. See “Welding Tips
1” included with the Ranger® 250 GXT (AU) for elec­trodes within the rating of this unit and recommended
welding currents of each.

TIG (CONSTANT CURRENT) WELDING

The recommended electrodes are .030” and .035” L­50 and L-56. They must be used with a blended
shielding gas such as C25 (75% Argon - 25% CO

The welding ranges that can be used with the
Ranger® 250 GXT (AU) are shown in the following
table:

Diameter Wire Speed Approximate

The Ranger® 250 GXT (AU) can be used in a wide variety of
AC and DC Tungsten Inert Gas (TIG) welding applications for
AC TIG Welding up to 200 amps and DC TIG welding up to 250
amps.

The K930 [ ] TIG Module installed on a Ranger® 250 GXT
(AU) provides high frequency and shielding gas control for AC

ARC GOUGING

and DC GTAW (TIG) welding processes. The TIG Module
allows full range output control.

The Ranger® 250 GXT (AU) can be used for limited
arc gouging.

When using the Ranger® 250 GXT (AU) for AC TIG welding of
aluminum the following settings and electrodes are recommend­ed:

Set the Range switch to adjust output current to the
desired level for the gouging electrode being used
according to the ratings in the following table:

SETTINGS FOR PURE TUNGSTEN

TUNGSTEN RANGE SWITCH APPROXIMATE
DIAMETER (in.) SETTINGS CURRENT RANGE

1/8 80 or 130 100 - 300 Amps
3/32 80 45 - 140 Amps
1/16 80 45 - 100 Amps

ELECTRODE SETTING CURRENT RANGE (DC, electrode positive)

RANGER® 250 GXT (AU)

(in.) Range In./Min. Current Range

.035 80 - 110 75A to 120A
.045 70 - 130 120A to 170A
.068 40 - 90 125A to 210A

5/64 50 - 75 180A to 235A

(in.) Range In./Min. Current Range

.030 75 - 300 50A to 130A
.035 100 - 250 80A to 175A
.045 125 - 200 145A to 200A

1/8 30 - 60 Amps
5/32 90 - 150 Amps
3/16 150 - 250 Amps

).

2

B-5

SUMMARY OF WELDING PROCESSES

CONTROL ELECTRODE

CABLE IDLE WHEN NOT TO START

PROCESS USED MODE WELDING WELDING

STICK No AUTO Hot Touch electrode to work.

WIRE FEED, LN-25 WITH No AUTO Cold Press gun trigger, LN-25
INTERNAL CONTACTOR contactor closes. Welding

TIG, TIG MODULE WITH Yes HIGH Cold Press Amptrol,
WITH CONTACTOR KIT contactor closes,
CONTROL CABLE, & welding starts immediately.
AMPTROL

OPERATION

Welding starts immediately
and engine goes to high
idle.

starts immediately and
engine goes to high idle.
Note: Output Control

must be set above “3”.

B-5

*

WIRE FEED, LN-15 No AUTO Cold Press gun trigger.
ACROSS the ARC LN-15 contactor closes,
(has internal contactor) Welding starts immediately

and engine goes to “HIGH”
Idle.
Note: Output Control must

be set above “3”.

*

*When welding with MIG wire instead of self-shielded

core wire, weld starts can be improved by setting the
idle mode to “HIGH”

.

RANGER® 250 GXT (AU)

C-1

ACCESSORIES

C-1

OPTIONAL EQUIPMENT (Field Installed)

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
K958-2 Lunette Eye Hitch
K959-2 Fender & Light Kit
K965-1 Cable Storage Rack

K1737-1 FOUR WHEEL ALL-TERRAIN UNDER­CARRIAGE - For moving by hand at construction

sites. Heavy duty puncture resistant pneumatic tires.

K1770-1 UNDERCARRIAGE (FACTORY) - For mov­ing by hand on a smooth surface. One or two gas
cylinders can be mounted on the rear of the undercar­riage with the installation of K1745-1 Cylinder
Holder(s). Heavy duty puncture resistant pneumatic
tires and front caster.

K1745-1 WELDING GAS CYLINDER LPG TANK
HOLDER

Holds Welding Gas Cylinder for use on K1770-1
Undercarriage. One or two may be installed on an
undercarriage.

K875 Accessory Kit - For Stick welding. Includes
20ft.(6.1m)#6 electrode cable with lug. 15ft.(4.6m)#6 work
cable with lugs, headshield, filter plate, work clamp, elec­trode holder and sample pack of mild steel electrode. 150
amp capacity.

K1898-1 Spark Arrester Kit - Attaches between muffler
and exhuast elbow. Virtually eliminates spark emissions.

K1788-1 ROLL CAGE - Gives added damage protection.
Attaches to K1737-1, K1770-1, and K957-1.

K886-2 Canvas Cover -To protect the Ranger® 250
GXT (AU) when not in use. Made from attractive red
canvas material which is flame retardant, mildew
resistant, and water repellent.

K857 (25 ft.(7.5m) or K857-1(100 ft.(30.4m)
Remote Control- Portable control provides same dial range

as the output control on the welder. Has a convenient 6-pin
plug for easy connection to the welder.

K704 Accessory Kit - Includes 35 ft (10.7m) 2/0 AWG elec­trode cable, 30 ft. (9.1m) 2/0 AWG work cable, headshield
with No. 12 filter, GC300 work clamp and Cooltong® 300
electrode holder. Cables are rated at 300 amps, 100% duty
cycle.

RANGER® 250 GXT (AU)

C-2

ACCESSORIES

RECOMMENDED EQUIPMENT

STICK

K704 Accessory Kit- (400 AMP Capacity) which
includes:

• Electrode Holder & Cable

• Work Clamp & Cable

• Headshield

K875 Accessory Kit- (150 AMP Capacity)

C-2

OPTIONAL TIG EQUIPMENT:

K939-1 Docking Kit - For Mounting the K930-2 TIG Module

on top of the Ranger® 250 GXT (AU).

K937-45 Control Cable Extension - Allows TIG Module to be
operated at distances up to 200ft. from the power source.
Available in 45ft. (13.7m).

K963-3 Hand Amptrol

K870 Foot Amptrol

WIRE FEED

K449 LN-25 - Includes internal contactor for across

the arc operation (no control cable). Provides “cold”
electrode until gun trigger is pressed. Includes gas
solenoid.

Magnum Gun and Magnum Gun Connector Kit are
required for gas-shielded welding. Innershield Gun is
required for gasless welding.

K126-2 Magnum 350 Innershield Gun
K1802-1 Magnum 300 MIG Gun (for LN-25)
K470-2 Magnum 300 MIG Gun (for LN-15)
K466-10 Connector Kit (for LN-15, K470-2)
K1500-1 Gun Receiver Bushing (for LN-15 & K126-2)
K1870-1 LN-15 Across the Arc Model

TIG

Magnum™ TIG Torch
K1783-4 - TIG Torch

Magnum Parts Kit and Argon Gas

REMOTE OUTPUT CONTROL

(See Operations Section for reference)

The Ranger® 250 GXT (AU) is equipped with a 6-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. When

remote control is used set the LOCAL / REMOTE switch in
the "REMOTE" position.

K930-2 TIG Module - Provides high frequency and shield­ing gas control.for AC and DC GTAW (TIG) welding applica­tions. Its compact case is designed foe easy carrying, com­plete with a handle. High frequency bypass is built in
Requires K938-1 Contactor Kit, K936-3 Control Cable, and

K814 Arc Start Switch.

K938-1 Contactor Kit - For use with TIG Module, Provides a

“cold” electrode until the triggering device (Arc Start Switch)
is pressed.

K936-3 Control Cable - Connects TIG Module to Ranger®
250 GXT (AU).

RANGER® 250 GXT (AU)

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

Have qualified personnel do the maintenance
work. Turn the engine off before working inside
the machine. In some cases, it may be necessary
to remove safety guards to perform required
maintenance. Remove guards only when
necessary and replace them when the mainte­nance requiring their removal is complete.
Always use the greatest care when working near
moving parts.

Do not put your hands near the engine cooling
blower fan. If a problem cannot be corrected by
following the instructions, take the machine to
the nearest Lincoln Field Service Shop.

-----------------------------------------------------------------------

ELECTRIC SHOCK can kill.

Do not touch electrically live parts

•
or electrode with skin or wet
clothing.

• Insulate yourself from work and

ground

-----------------------------------------------------------------------

-----------------------------------------------------------------------

------------------

See additional warning information

throughout this operatorʼs manual and
the Engine manual as well.

-----------------------------------------------------------------------

Read the Safety Precautions in the front of this manual
and the engine instruction manual before working on
this machine.

Keep all equipment safety guards, covers, and devices
in position and in good repair. Keep hands, hair, cloth­ing, and tools away from gears, fans, and all other
moving parts when starting, operating, or repairing the
equipment.

• Always wear dry insulating gloves.

ENGINE EXHAUST can kill.

Use in open, well ventilated areas

•
or vent exhaust outside.

MOVING PARTS can injure.

Do not operate with doors open or

•
guards off.

• Stop engine before servicing.

• Keep away from moving parts.

-----------------------------------------------------

CAUTION

Make certain that the oil filler cap is securely tight­ened after checking or adding oil. If the cap is not
tight, oil consumption can increase significantly
which may be evidenced by white smoke coming
from the exhaust.

OIL - Maintenance schedule for changing the oil and

•

oil filter after break-in :

Kohler

CH23S, CH680, CH730

Oil 100 Hrs.

Oil Filter 200 Hrs.

The above schedule is for normal operating condi­tions. More frequent oil changes are required with
dusty, high temperature and other severe operating
conditions. Refer to the maintenance section of the
Engine Owner's Manual for more information.

: Engine life will be reduced if the oil and oil

NOTE

filter are not changed according to the manufacturerʼs
recommendation.

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
yellow cap from the oil drain valve and attach the
flexible drain tube supplied with the machine. Push
in and twist the drain valve counterclockwise. Pull
the valve out and drain the oil into a suitable contain­er.

• Close the drain valve by pushing in and twisting
clockwise. Replace the yellow cap.

• Refill to the upper limit mark on the dipstick with the
recommended oil. Tighten the oil filler cap securely.

ENGINE OIL REFILL CAPACITIES

Without oil filter replacement:

• 1.7qt. (1.6 liter)-Kohler

With oil filter replacement:

• 2.0qt. (1.9 liter)-Kohler

Routine Maintenance

• 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.

RANGER® 250 GXT (AU)

D-2

Use 4-stroke motor oil that meets or exceeds the
requirements 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.

SAE 10W-30 is recommended for general, all-tempera­ture use, -5 F to 104 F (-20 C to 40 C).

See Engine Ownerʼs Manual for more specific informa­tion on oil viscosity recommendations.

MAINTENANCE

D-2

AIR CLEANER AND OTHER MAINTENANCE

• Air Cleaner - With normal operating conditions, the
maintenance schedule for cleaning and re-oiling
the foam pre-filter is every 25 hours and replace­ment of the air cleaner filter every 100 hours.
More frequent servicing is required with dusty
operating conditions. Refer to the maintenance
section of the Engine Ownerʼs Manual for more
information.

Wash your hands with soap and water after handling
used oil.

Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you take
it in a sealed container to your local service station or
recycling center for reclamation.

Do not throw it in the trash, pour it on the ground or
down a drain.

OIL FILTER CHANGE

1. Drain the engine oil.

2. Remove the oil filter, and drain the oil into a suitable
container. Discard the used oil filter.

3. Clean the filter mounting base, and coat the gasket
of the new oil filter with clean engine oil.

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.

• Refer to the maintenance section of the Engine
Ownerʼs Manual for the maintenance schedule,
spark plug servicing, cooling system servicing, and
fuel filter replacement.

• Blow out the machine with low pressure air period­ically. In particularly dirty locations, this may be
required once a week.

• Output Ranger Selector and Polarity Switches:

Switch contacts should not be greased. To keep
contacts clean, rotate the switch through its entire
range frequently. Good practice is to turn the han­dle from maximum to minimum setting twice each
morning before starting to weld.

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 neces­sary, add oil to the upper limit mark on the dipstick.

RANGER® 250 GXT (AU)

D-3

MAINTENANCE

D-3

ENGINE ADJUSTMENTS

OVERSPEED IS HAZARDOUS

WARNING

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.

-----------------------------------------------------------------------

Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.

SLIP RINGS

A slight amount of darkening and wear of the slip rings
and brushes is normal. Brushes should be inspected
when a general overhaul is necessary.If brushes are
to be replaced, clean slip rings with a fine emery
paper.

CAUTION

Do not attempt to polish slip rings while engine is
running.

-----------------------------------------------------------------------

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes away from battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY - disconnect negative
cable from old battery first and connect 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.

• USING A BOOSTER - connect positive lead to battery
first then connect negative lead to engine foot.

BATTERY ACID CAN BURN EYES AND SKIN.

• Wear gloves and eye protection and be careful when
working near battery. Follow instructions printed on
battery.

BATTERY

1. When replacing, jumping, or otherwise connecting
the battery to the battery cables, the proper
polarity must be observed. Failure to observe
the proper polarity could result in damage to the
charging circuit. The positive (+) battery cable
has a red terminal cover.

2. If the battery requires charging from an external
charger, disconnect the negative battery cable
first and then the positive battery cable before
attaching the charger leads. Failure to do so
can result in damage to the internal charger
components. When reconnecting the cables,
connect the positive cable first and the negative
cable last.

HARDWARE

Both English and Metric fasteners are used in this
welder.

ENGINE MAINTENANCE PARTS

KOHLER C23S, CH680

KOHLER 12 050 01

Oil Filter FRAM PH8172*

Air Filter KOHLER 47 083 03

KOHLER C730

KOHLER 12 050 01

FRAM PH8172*

KOHLER 47 083 03

Element FRAM CA79

Air Filter KOHLER 24 083 02

KOHLER 24 083 02

Pre-Cleaner

Fuel Filter KOHLER 24 050 13

Spark Plugs CHAMPION RC12YC
(Resistor (.030” GAP)

KOHLER 24 050 13

CHAMPION RC12YC

(.030” GAP)

Type)

* Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.

RANGER® 250 GXT (AU)

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.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

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.

If you do not understand or are unable to perform the
Recommended Course of Action safely, 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 GXT (AU)

E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

No welder output power or Auxiliary
Power.

Engine will not idle down to low
speed.

1. Open in miscellaneous leads.

2. Open lead in flashing or field
circuit.

3. Faulty rotor.

4. Faulty Potentiometer (R1).

5. Faulty stator Field winding.

6. Faulty Field rectifier (On PCB*).

7. Faulty P.C. Board.

1. Idler switch on High Idle.

2. Insufficient voltage present on
idler solenoid terminals.
(Voltage should be 12V to 14V
DC).

3. External load on welder or
auxiliary power.

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
attempting to weld.

* Printed Circuit Board (PCB)

4. Faulty wiring in solenoid circuit.

5. Faulty idler solenoid.

6. Faulty P.C. Board.

1. Poor work lead connection to
work.

2. No voltage signal from the
current sensor.

3. No open circuit voltage on
output studs.

4. Faulty P.C. Board.

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 GXT (AU)

E-3

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-3

Engine will not go to high idle when
using auxiliary power.

Engine will not crank or is hard to
crank.

Engine shuts down.

1. No voltage signal from the
current sensor.

2. Auxiliary power load less than
100 to 150 watts.

3. Faulty P.C. Board.

1. Battery will not hold a charge.
Faulty Battery.

2. No or insufficient charging
current.

3. Loose battery cable
connection(s).

1. Out of fuel.

2. Low oil level.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

Engine does not develop full power.

Engine is hard to start.

1. Fuel filter clogged.

2. Air filter clogged.

1. Spark plugs do not have
specified gap.

2. Spark plugs are fouled.

3. Out of fuel.

4. Fuel filter clogged.

5. Electric fuel pump not working.

6. Mechanical fuel pump not work­ing.

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 GXT (AU)

F-1

Enhanced Diagram

WIRING DIAGRAM

F-1

RANGER® 250 GXT (AU)

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the

machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-2

DIAGRAMS

F-2

RANGER® 250 GXT (AU)

F-3

CI

RCU

IT

B

R

EA

KERS

.

DIMENSION PRINT

F-3

10.78

7

10.2

7.22

4

36.2

33.62

CODES.

B

M20512

ALL

29.88

CH

MAT

CS MAY NOT

IT

RCU
CI

KE
EA

APHI
R

G

RONT

NK

ITH OIL

FUEL TA

W

ITY

PTY

V

EM

AND

OF GRA

E
N

CENTER

IN ENGI

14.75

19.50

17.50

: CASE F

E
T

NO

0

6

20.8

21.00

24.8

0

42.1

2.6

0

41.2

TRUCK / UNDERCARRIAGE MOUNTING HOLES

DIMENSION DIAGRAM CODES 11689, 11741, 11796, 11803

RANGER® 250 GXT (AU)

F-4

DIAGRAMS

MM

INCH

36.24

920.43

33.62

853.97

29.88

758.95

10.78

273.93

10.27

260.98

7.22

183.39

CIRCUIT

BREAKERS

F-4

A

M24957

NOTE: CASEFRONT GRAPHICS MAY NOT MATCH ALL CODES.

CENTER OF GRAVITY WI TH OIL

IN ENGINE AND EMPTY FUEL TANK.

22.00

558.8

20.80

528.28

24.86

631.33

10.75

273.05

42.10

1069.46

DIMENSION DIAGRAM CODE 12099, 12194, 12205

2.6

66.55

19.50

495.3

17.50

444.5

41.20

1046.48

TRUCK/UNDERCARRIAGE MOUNTI NG HOLES

RANGER® 250 GXT (AU)

NOTES

RANGER® 250 GXT (AU)

PARTS LIST FOR

Ranger

P-645P-645

®

250 GXT (AU)

This parts list is provided as an informative guide only.

It was accurate at the time of printing. These pages are only updated on the
Service Navigator DVD and in Lincoln Electricʼs official Parts Book (BK-34).

When ordering parts, always refer to Lincoln Electricʼs official Parts Book
(BK-34) for the latest pages.

RANGER®250 GXT (AU)

ILLUSTRATION OF SUB ASSEMBLIES

7

5

6

4

3

1

2

P-645-AP-645-A

RANGER

®

250 GXT (AU)

04-23-2013

P-645-A.1P-645-A.1

Ranger®250 GXT (AU)

For Codes: 11689, 11741, 11796, 11803, 12099, 12194 & 12205

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any
code numbers not listed.

Use the Main Assembly drawing on the left hand page and the table below to determine which sub assembly
page and column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBLY

PAGE NAME

Miscellaneous Items

PAGE NO.

CODE NO.

11689 11111111

11741 11111112

11796 11122113

P-645-B.2

1

Case Front (Upper)

P-645-C

2

Case Front (Lower)

P-645-D

3

Base/Fuel Tank/Battery

P-645-E

Assembly

4

Engine Assembly

P-645-F

5

Blower Baffle Assembly

P-645-G

6

Stator/Rotor Assembly

P-645-H

7

Covers & Case Back Assembly

P-645-J

11803 11132112

12099 11142114

12194 11242114

12205 11252114

RANGER

®

250 GXT (AU)

Oct-13

P-645-B.2

MISCELLANEOUS ITEMS

(THESE ITEMS ARE NOT ILLUSTRATED)

P-645-B.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Spark Arrestor Clamp S20462 1 X

RANGER

®

250 GXT (AU)

04-23-2013

NOTES

RANGER®250 GXT (AU)

Case Front (Upper)

1A

7A

8

3A

5A

4A

26

29

21

23

58A

25A

25B

57A

59A

50

58A

P-645-CP-645-C

26

23

58A

7A

58A

5A

29

21

3A

1A

50

25B

4A

57A

25A

59A

RANGER

®

250 GXT (AU)

04-23-2013

P-645-C.1

P-645-C.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Case Front Assembly (G3666-52), Includes: NSS 1X

1A Case Front G3860-13 1 X
3A Top Bezel G3593 1 X
3B Self Tapping Screw (Not Shown) S24738-1 7 X
4A Right Bezel G3594-1 1 X
4B Self Tapping Screw (Not Shown) S24738-1 2 X
5A Left Bezel G3594-2 1 X
5B Self Tapping Screw (Not Shown) S24738-1 2 X
7A Choke Control S7525-21 1 X
7B Choke Control Bushing (Not Shown) S25335 1 X
7C Plain Washer (Not Shown) S9262-4 1 X
8 Rotary Switch S25686 1 X
21

Nameplate G6782-3

1X
23 Knob T10491-1 1 X
24 “O” Ring (Not Shown) T13483-7 1 X
25 Harness Asbly, Includes: G4810-4 1 X
25A Potentiometer T10812-119 1 X
25B Potentiometer Spacer S18280 1 X
26 Engine Switch Handle S25718 1 X
29 Fuel/Hour Meter M22209 1 X
50 Fastener Button T14659-1 1 X
55 Thread Forming Screw (Not Shown) S9225-68 4 X
57A Selector Switch Mounting Asbly M17013-3 1 X
57B #10-24 HLN (Not Shown) T9187-9 2 X
57C Spacer (Not Shown) S21985 1 X
57D Thread Forming Screw (Not Shown) S9225-4 1 X
58A Control Handle M16493 2 X
58B Self Tapping Screw (Not Shown) S8025-78 2 X
59A Arc Polarity Switch Asbly M17014-1 1 X
59B #10-24 HLN (Not Shown) T9187-9 2 X
61 Lubrication Tag (Not Shown) T11590-151 1 X

#

NSS - Not Sold Separately

RANGER

®

250 GXT (AU)

04-23-2013

Case Front (Lower)

56

51A

14A

15B

28

20

19

51B

31

6A

9A

15A

27A

16

12

15D

6B

6C

6E

6F

6D

25

36

35

22

P-645-DP-645-D

14A

15B

12

35

15A

16

36

27A

9A

25

15D

31

28

51B

51A

56

RANGER

20

®

250 GXT (AU)

19

22

6B

6A

6E

6F

6D

6C

04-23-2013

P-645-D.1

P-645-D.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

6A Output Terminal Assembly, Includes: T14166-9 2 X X
6B Output Stud Nut T3960 2 X X
6C Self Tapping Screw S8025-91 4 X X
6D 1/2-13 x .875 HHCS CF000344 2 X X
6E Plain Washer S9262-1 2 X X
6F Lock Washer E106A-15 2 X X
9A RCD Strap S28425 1 X •
9A RCD Strap Assembly (Not Shown) S28425-3 1 • X
9B Thread Forming Screw (Not Shown) S922-63 2 X X
12 Circuit Breaker (20 Amp) 250VAC, 50VDC T12287-38 1 X X
13 Sealing Boot (Not Shown) S22061-2 3 X X
14A Receptacle M22425 2 X X
14B #6-32 x 1.25 RHS (Not Shown) CF000050 8 X X
14C Lock Washer (Not Shown) E106A-13 8 X X
14D #6-32 HN (Not Shown) CF000005 8 X X
15A RCD (NHP) S28343 1 X X
15B Receptacle Cover S28344-2 1 X •
15B Boot (Not Shown) G7594 1 • X
15C #10-24 HN (Not Shown) CF000010 2 X X
15D Terminal Strip S15389-1 1 X X
15E #10-24 HLN (Not Shown) T9187-9 3 X X
15F Plain Washer (Not Shown) S9262-27 2 X X
16 Circuit Breaker T12287-34 2 X X
19 1/4-20 HJLN T9187-1 1 X X
20 1/4-20 HN CF000017 1 X X
22 Rating Plate L12790-9 1 X X
25 Toggle Switch (Part of G4810-4 Harness) T10800-39 1 X X
27A Adapter Plate S25928 1 X X
27B Self Tapping Screw (Not Shown) S8025-98 2 X X
28 Self Tapping Screw S8025-96 2 X X
31 Connector Cap S17062-10 1 X X
35 Amphenol Bypass PC Board Assembly M20463-[ ] 1 X X
36 Sealing Boot S22061-4 1 X X
51A Output Stud Cover Plate S25669 2 X X
51B Thread Forming Screw S9225-66 4 X X
56 Output Stud Cover M20007 2 X X
57 Decal (Not Shown) S28434 1 X X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along
with any necessary jumpers or adapters. The dash number brackets [ ] have purposely
been left blank so as to eliminate errors, confusion and updates.

®

RANGER

250 GXT (AU)

Oct-13

Base/Fuel Tank/Battery Assembly

2B

1

5B

5A

11A

21A

13A

8A

8C

8D

8E

8B

7

10

4C

4D

2A

17A

17G

17F

17F

17H

17H

17E

17C

17B

17D

4E

4G

4F

4A

4B

22

P-645-EP-645-E

11A

5A

4A

4F

4B

4E

4G

10

8A

4C

4D

8C

8D

8E

17G

17F

17F

17H

17H

17B

17A

17E

17C

2A

17D

13A

8B

2B

21A

22

5B

RANGER

®

250 GXT (AU)

04-23-2013

P-645-E.1

P-645-E.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Base G3870-3 1 XXXXX
2A Engine Cross Support L11147-1 1 XXX• •
2A Engine Cross Support L11147-2 1 •••XX
2B Thread Forming Screw S9225-68 6 XXXXX
4 Fuel Tank & Assembly, Includes: L12164-1 1 X ••••
4 Fuel Tank & Assembly, Includes: L12164-4 1 • X • X •
4 Fuel Tank & Assembly, Includes: L12164-6 1 ••••X
4 Fuel Tank & Assembly, Includes: L16027 1 • • X • •
4A Fuel Tank NSS 1 XXXXX
4B Fuel Sender M20302 1 XXXXX
4C Fuel Pick-Up Tube Assembly S19565-4 1 XXXXX
4D Rubber Plug S19563 1 XXXXX
4E Fuel Cap S20541 1 X••••
4E

Ratchet Fuel Cap (No longer part of Fuel Tank Asbly)

S28521 1 • XXXX
4F Remote Vent Valve M22694 1 • XXXX
4G Rubber Plug S28522 1 • XXXX
4H EPA Compliance Decal (Not Shown) NSS 1 • XXXX
5A Stator Support L12329-2 1 XXXXX
5B Thread Forming Screw S9225-68 6 XXXXX
7 12 Volt Storage Battery (M9399-14) NSS 1 XXXXX
8A Battery Bracket S27320-1 1 XXXXX
8B J-Bolt T8818-14 2 XXXXX
8C Lock Washer E106A-2 2 XXXXX
8D Plain Washer S9262-98 2 XXXXX
8E 1/4-20 HN CF000017 2 XXXXX
9A Battery Cable (Neg.) (Not Shown) S8070-20 1 XXXXX
9B Battery Cable (Pos.) (Not Shown) S8070-11 1 XXXXX
9C Battery Terminal Cover (Not Shown) S20191-1 1 XXXXX
9D Plastic Cap (Not Shown) T14654 1 XXXXX
10 Fuel Tank Brace G4003-2 1 XXXXX
11A Reactor Assembly L12326-3 1 XXXXX
11B Self Tapping Screw (Not Shown) S9225-66 2 XXXXX
13A Choke Coil & Lamination Assembly L9036-3 1 XXXXX
13B Self Tapping Screw (Not Shown) S9225-68 4 XXXXX
17A Electric Fuel Pump M20393 1 XXXXX
17B Fuel Pump Bracket S25778 1 XXXXX
17C Thread Forming Screw S9225-68 4 XXXXX
17D Plain Washer S9262-98 2 XXXXX
17E Flex Tube (Supplied w/Engine) NSS 1 XXXXX
17F Flex Tube T10642-275 2 XXXXX
17G Fuel Filter (Supplied w/Engine) NSS 1 XXXXX
17H Hose Clamp T13777-7 4 XXXXX
21A Hinge Assembly S24295-2 2 XXXXX
21B Rivet (Not Shown) T12584-9 4 XXXXX
22 EPA Compliance Decal NSS 1 • XXXX
25 Flex Tube (Not Shown) (Fuel Tank Vent Hose) T10642-339 1 • X X • •
25 Flex Tube (Not Shown) (Fuel Tank Vent Hose) T10642-321 1 •••XX

NSS - Not Sold Separately

RANGER

®

250 GXT (AU)

Oct-13

Engine Assembly

2A

1E

1A

1B

1E

1C

1F

P-645-FP-645-F

1A

2A

1E

1B

RANGER

®

250 GXT (AU)

1E

1F

1C

04-23-2013

P-645-F.1

P-645-F.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Engine (M21300) - Kohler NSS 1X••
1A Engine (M22704) - Kohler NSS 1•X•
1A Engine (M24866) - Kohler NSS 1 ••X
1B Rubber Mounting S24344 2 X X X
1C 3/8-16 x 2.50 HHCS CF000196 2 X X X
1D Plain Washer (Not Shown) S9262-120 2 X X X
1E Plain Washer S9262-113 6 X X X
1F Lock Washer E106A-16 2 X X X
1G 3/8-16 HN (Not Shown) CF000067 2 X X X
2A Muffler Assembly (Kohler) G3574-4 1 X X X
2B Exhaust Gasket (Supplied w/Engine) (Not Shown) M16999-1 2 X X X
5 Outlet Pipe Elbow (Not Shown) M16980-1 1 X X X

NSS - Not Sold Separately

RANGER

®

250 GXT (AU)

04-23-2013

Blower Baffle Assembly

17

11

10

10

1

7A

7B

3

P-645-GP-645-G

7A

11

10

10

7B

17

RANGER

®

250 GXT (AU)

04-23-2013

P-645-G.1

P-645-G.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Baffle G4730-1 1 X
3 Rectifier Assembly L11411-1 1 X
7A Weld Control PC Board Assembly L12198-[ ] 1 X
7B Self Tapping Screw S8025-100 3 X
10 Bushing T12380-1 2 X
11 Bushing T12380-12 1 X
17 Thread Forming Screw S9225-68 2 X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along
with any necessary jumpers or adapters. The dash number brackets [ ] have purposely
been left blank so as to eliminate errors, confusion and updates.

RANGER

®

250 GXT (AU)

04-23-2013

Stator/Rotor Assembly

8A

8B

11

10

12

13

9A

7A

6A

6C

6E

6D

6F

6C

6B

2A

2B

1A

1G

1D

1C

1B

1E

1F

5B

15A

5A

P-645-HP-645-H

2A

2B

1A

7A

1C

1B

1E

5A

1F

5B

15A

6D

6A

6C

6E

8A

6F

8B

9A

11

10

1D

1G

13

12

6C

RANGER®250 GXT (AU)

6B

04-23-2013

P-645-H.1

P-645-H.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Rotor & Shaft Assembly L10825 1 X
1B Centering Washer S20110-3 1 X
1C Special Hex Head Bolt T14843-3 1 X
1D Tolerance Ring S18044-9 1 X
1E Blower L9033 1 X
1F Plain Washer S9262-149 1 X
1G Bearing M9300-85 1 X
2A Firewall G3849-1 1 X
2B Bushing T12380-1 1 X
2C Bushing (Not Shown) T12380-6 1 X
2D Door Bumper (Not Shown) T14882-1 2 X
5A Brush & Brush Holder Assembly, Includes: M16158 1 X

Brush Holder Cartridge G2114 1 X
Brush Assembly, Includes: S19480 2 X

Brush Clip S19475 2 X
Compression Spring T11862-44 2 X
Brush S19474 2 X

Brush Assembly Retainer M16157 1 X
5B Brush Holder Bracket M18925 1 X
5C Self Tapping Screw (Not Shown) S8025-91 2 X
5D 1/4-20 x 1.00 HHCS (Not Shown) CF000015 2 X
5E Lock Washer (Not Shown) E106A-2 2 X
5F 1/4-10 HN (Not Shown) CF000017 2 X
6A Rubber Mounting S24344 2 X
6B 3/8-16 x 2.00 HHCS CF000071 2 X
6C Plain Washer S9262-113 4 X
6D 3/8-16 HN CF000067 2 X
6E Plain Washer S9262-120 2 X
6F Lock Washer E106A-16 2 X
7A Stator Frame Assembly G2618-11 1 X
7B 3/8-16 x 1.25 HHCS (Not Shown) T8833-10 2 X
7C Lock Washer (Not Shown) E106A-4 2 X
8A Solenoid Assembly S20752 1 X
8B Self Tapping Screw S8025-91 3 X
9A Pull Wire S20848 1 X
9B Bracket (Not Shown) S21177 1 X
9C Bushing, Linkage Retaining (Not Shown) S21015 2 X
10 Spring T6778 1 X
11 Plunger S21020 1 X
12 Plain Washer S9262-98 1 X
13 1/4-20 HJN T9187-1 1 X
15A Clamp S24305 1 X
15B Thread Forming Screw (Not Shown) S9225-26 1 X
15C Plain Washer (Not Shown) S9262-121 1 X
15D Lock Washer (Not Shown) E106A-14 1 X

Flex Tube (Oil Drain) (On Slots of Firewall) (Not Shown)

20

T10642-242 1 X

RANGER

®

250 GXT (AU)

04-23-2013

Covers & Case Back Assembly

7

8

4B

4A

20

14

19

18

11

12

6B

6A

13

15

6C

5A

3A

25A

25B

10

15

2A

1A

6E

9A

9B

16

23

9B

P-645-JP-645-J

3A

4A

14

2A

9A

16

23

25A

25B

10

4B

19

18

12

11

20

5A

15

6B

1A

13

15

RANGER

6C

®

250 GXT (AU)

6A

6E

04-23-2013

P-645-J.1

P-645-J.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Case Side - Right G3510 1 XXXX
1B Thread Forming Screw (Not Shown) S9225-68 3 XXXX
2A Case Side - Left G3511 1 XXXX
2B Thread Forming Screw (Not Shown) S9225-68 3 XXXX
3A Case Back (Includes Item 23) G3865-4 1 XXXX
3B Thread Forming Screw (Not Shown) S9225-68 4 XXXX
3C Fastener Button (Not Shown) T14659-1 2 XXXX
4A Roof G3882-4 1 X • • •
4A Roof G3882-6 1 • X X X
4B Thread Forming Screw S9225-68 16 XXXX
4C Door Bumper (Not Shown) T14882-1 6 XXXX
5A Left Engine Cover L11529-1 1 XXXX
5B Thread Forming Screw (Not Shown) S9225-66 1 XXXX
5C Speed Nut (Not Shown) T11525-5 1 XXXX
6A Right Engine Cover, Includes: L11528 1 XXXX
6B Latch S24694 1 XXXX
6C Hinge S24348 2 XXXX
6D Rivet (Not Shown) T12584-12 6 XXXX
6E Oil Drain Decal S24665 1 XXXX
7 Fuel Trough L12084 1 XXXX
8 Cover Seal S12934-1 1 XXXX
9A Engine Top Cover Welded Assembly G3514 1 X • • •
9A Engine Top Cover Welded Assembly G3514-2 1 • X X X
9B Latch S24694 1 XXXX
9C Door Bumper (Not Shown) T14882 2 XXXX
9D Rivet (Not Shown) T12584-6 4 XXXX
9E Rivet (Not Shown) T12584-9 4 X X • •
9E Rivet (Not Shown) T12584-12 4 • • X X
10 Battery Caution Decal S17851 1 XXXX
11 Warning Label M16197 1 XXXX
12 Fuel Warning Decal T13086-108 1 XXXX
13 Wiring Diagram M22491 1 XXXX
14 Warranty Decal Part of L12790-9 1 XXXX
15 Logo Decal S27368-5 2 XXXX
16 Engine Decal S26884 1 XXX•
16 Engine Service Decal S29943 1 •••X
18 Warning Decal S25896 1 XXXX
19 CO Warning Decal M21436 1 XXXX
20 Family Decal M21952-1 2 XXXX
23 Foam Airbox M22367 1 XXXX
25A Battery Cover M22185 1 XXXX
25B Thread Forming Screw S9225-68 3 XXXX
26 Fuel Filling Warning Decal (Not Shown) T13086-215 1 XXXX

#

RANGER

®

250 GXT (AU)

04-23-2013

NOTES

RANGER®250 GXT (AU)

NOTES

RANGER® 250 GXT (AU)

WARNING

Spanish

AVISO DE

PRECAUCION

 Do not touch electrically live parts or

electrode with skin or wet clothing.

 Insulate yourself from work and

ground.

 No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

 Aislese del trabajo y de la tierra.

 Keep flammable materials away.

 Mantenga el material combustible

fuera del área de trabajo.

 Wear eye, ear and body protection.

 Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

 Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

 Isolez-vous du travail et de la terre.

 Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

 Isolieren Sie sich von den

Elektroden und dem Erdboden!

 Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

 Isole-se da peça e terra.

 Gardez à l’écart de tout matériel

inflammable.

 Entfernen Sie brennbarres Material!

 Mantenha inflamáveis bem guarda-

dos.

 Protégez vos yeux, vos oreilles et

votre corps.

 Tragen Sie Augen-, Ohren- und Kör-

perschutz!

 Use proteção para a vista, ouvido e

corpo.

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 HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

 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

 Los humos fuera de la zona de res-

piración.

 Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

 Gardez la tête à l’écart des fumées.
 Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

 Vermeiden Sie das Einatmen von

Schweibrauch!

 Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

 Mantenha seu rosto da fumaça.
 Use ventilação e exhaustão para

remover fumo da zona respiratória.

 Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

 Débranchez le courant avant l’entre-

tien.

 Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

 Não opere com as tampas removidas.
 Desligue a corrente antes de fazer

serviço.

 Não toque as partes elétricas nuas.

 No operar con panel abierto o

guardas quitadas.

 N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

 Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

 Mantenha-se afastado das partes

moventes.

 Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

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.

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and
selling high quality welding equipment, consumables, and cutting
equipment. 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 possession at that time. Lincoln Electric is not in a position to
warrant or guarantee such advice, and assumes no liability, with
respect to such information or advice. We expressly disclaim any
warranty of any kind, including any warranty of fitness for any
customer’s 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.

Subject to Change – This information is accurate to the best of our
knowledge at the time of printing. Please refer to
www.lincolnelectric.com for any updated information.