Lincoln Electric IM921 User Manual

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RANGER ®250 GXT

For use with machines having Code Numbers:

11400, 11420, 11493, 11667, 11668, 11736, 11737,

11792, 11793, 11799, 11800, 12095, 12201

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM921-F | Issue D ate Aug- 13

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: globalservice@lincolnelectric.com

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:

Diesel Engines

Gasoline Engines

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

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

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.

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.

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

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

Your Product”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register

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.

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

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

Premises Wiring ...................................................................................................................A-9

________________________________________________________________________________

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-505, P-634

________________________________________________________________________

Ranger®250 GXT ...........................................................A-7

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - Ranger®250 GXT ( K2382-3, -4 and -5)

INPUT - GASOLINE ENGINE

Make/Model

Kohler CH20S, 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)

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)

10,000 Watts Continuous, 60 Hz AC

11,000 Watts Peak, 60 Hz AC

120/240 Volts

RECEPTACLES AND CIRCUIT BREAKERS

RECEPTACLES

(2) 120VAC Duplex (5-20R)

(1) 120/240VAC Dual Voltage

Full KVA (14-50R)

AUXILIARY POWER CIRCUIT BREAKER

Two 20AMP for Two Duplex Receptacle

(1) 50AMP for Dual Voltage (2-pole)

BATTERY CHARGING CIRCUIT BREAKER

20AMP for Engine Battery

Charging Circuit

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

Codes 11800 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.)

Codes 12095, 12096

574 lbs. (260kg.)

ENGINE COMPONENTS

LUBRICATION VALVE LIFTERS FUEL SYSTEM GOVERNOR

Full Pressure Hydraulic Mechanical Fuel Pump on K2382-3 Mechanical Governor

with Full Flow Filter Additional electric fuel lift pump

5% Regulation on K2382-4, -5.

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.

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

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)

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

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

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

OIL

LUBRICATION SYSTEM CAPACITY

Kohler CH20S, 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.

to the RANGER

(INCLUDING FILTER)

GXT is shipped with the engine

GXT base or weld

GXT base.

BATTERY CONNECTIONS

drill holes

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

CAUTION

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

1/0 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 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

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 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.

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

GXT

• 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

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 cy equipment, the bypass capacitor must be installed, order kit T12246.

250 GXT.

250 GXT is used with any other high frequen-

RANGER®250

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

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 is 100%.

Ranger®250 GXT

Constant Current 250 Amps AC @ 25 Volts

250 Amps DC @ 25 Volts

Constant Voltage 250 Amps DC @ 25 Volts

AUXILIARY POWER

A-6

120/240 VOLT DUAL VOLTAGE RECEPTACLE

The 120/240 volt receptacle can supply up to 42 amps of 240 volt power to a two wire circuit, up to 42 amps of 120 volts power from each side of a three wire circuit (up to 84 amps total). Do not connect the 120 volt circuits in parallel. Current sensing for the automatic idle feature is only in one leg of the three wire circuit as shown in the following column.

GND

The Ranger®250 GXT can provide up to 10,000 watts of 120/240 volts AC, single phase 60Hz power for continuous use, and up to 11,000 watts of 120/240 volts AC, single phase 60Hz power peak use. The front of the machine includes three receptacles for connecting the AC power plugs; one 50 amp 120/240 volt NEMA 14-50R receptacle and two 20 amp 120 volt NEMA 5-20R receptacles. Output voltage is within +/-10% at all loads up to rated capacity.

All auxiliary power is protected by circuit breakers. the 120V has 20 Amp circuit breakers for each duplex receptacle. The 120/240V Single Phase has a 50 Amp 2-pole Circuit Breaker that disconnects both hot leads simultaneously.

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.

120 V

240 V

120 V*

*Current Sensing for Automatic Idle. (Receptacle viewed from front of Machine)

120 V DUPLEX RECEPTACLES

The 120V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs.

The current rating of any plug used with the system must be at least equal to the current load through the associated receptacle.

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 20 amperes (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. This may necessitate 240V operation only.

Ranger®250 GXT Extension Cord Length Recommendations

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

Current

(Amps)

15 20 15 20 42

Voltage

Volts

120 120 240 240 240

Load

(Watts)

1800 2400 3600 4800

10,000

Conductor size is based on maximum 2.0% voltage drop.

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

14 AWG

30 (9)

60 (18)

12 AWG 40 (19)

30 (9) 75 (23) 60 (18)

10 AWG 75 (23) 50 (15)

150 (46) 100 (30)

50 (15)

8 AWG 125 (38) 88 (27) 225 (69) 175 (53)

90 (27)

6 AWG 175 (53) 138 (42) 350 (107) 275 (84)

150 (46)

RANGER®250 GXT

4 AWG 300 (91) 225 (69) 600 (183) 450 (137)

225 (69)

A-7

INSTALLATION

CAUTION

Certain Electrical devices cannot be powered to this Product. See Table A.2

TABLE lll

ELECTRICAL DEVICE USE WITH THIS PRODUCT

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-

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.

A-7

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

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

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 THIS PRODUCT

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product.

RANGER®250 GXT

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 the 120V or 240V supply (not both at the same time). 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) @ 120V

Max. Stick or Wire

Feed Setting None 0 0

180 Stick Setting 5100 42 21

130 Stick Setting 7200 60

80 Stick Setting 8750 72

*-or- @ 240V

** 30

** 36

A-8

1. Install a double pole, double throw switch between the power company meter and the premises disconnect.

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

2. Take necessary steps to assure load is limited to the capacity of the Ranger

50 amp 240V double pole circuit breaker. Maximum rated load for the 240V auxiliary is 42 amperes. Loading above 42 amperes will reduce output voltage below the allowable -10% of rated voltage which may damage appliances or other motor-driven equipment.

3. Install a 50 amp 120/240V plug (NEMA type 14-50) to the Double Pole Circuit Breaker using No. 8, 4 conductor cable of the desired length. (The 50 amp 120/240V plug is available in the optional plug kit.)

250 GXT by installing a

No Welding 10,000 84

** 42

* Each duplex receptacle is limited to 20 amps.

**Not to exceed 50A per 120VAC branch circuit when

splitting the 240 VAC output.

STANDBY POWER CONNECTIONS

The Ranger

250 GXT is suitable for temporary, standby, or emergency power using the engine manufacturerʼs recommended maintenance schedule.

The Ranger

250 GXT can be permanently installed as a standby power unit for 240V-3 wire, single phase 42 ampere service.

WARNING

(Connections must be made by a licensed electrician who can determine how the 120/240V power can be adapted to the particular installation and comply with all applicable electrical codes.) The following information can be used as a guide by the electrician for most applications (refer also to the connection diagram shown in Figure 1.)

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

4. Plug this cable into the 50 amp 120/240V

receptacle on the Ranger

250 GXT case front.

RANGER®250 GXT

A-9

INSTALLATION

Figure 1

CONNECTION OF Ranger®250 GXT TO PREMISES WIRING

A-9

WARNING

Connection of Ranger®250 GXT to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes.

RANGER®250 GXT

B-1

OPERATION

SAFETY PRECAUTIONS

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

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 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 11792 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

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 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 10,000 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)

1.48 Gallons/Hour) (5.62 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 (5.69 Liters/Hour)

1.74 Gallons/Hour (6.59 Liters/Hour)

1.62 Gallons/Hour (6.13 Liters/Hour)

1.90 Gallons/Hour) (7.19 Liters/Hour)

RANGER®250 GXT

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.

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 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:

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

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

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.

B-4

OPERATION

WELDING PROCESS

For any electrodes the procedures should be kept within the rating of the machine. For electrode infor-

mation 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.

RANGE SETTING TYPICAL CURRENT RANGE

ELECTRODE SIZE

80 MAX.

130 MAX.

180 MAX.

250 MAX.

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

3/32

1/8

5/32

3/16

50 TO 80 AMPS

70 TO 130 AMPS

110 TO 180 AMPS

160 TO 250 AMPS

250 GXT for elec-

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

put 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.

WIRE FEED WELDING PROCESSES (CONSTANT VOLTAGE)

The Innershield the Ranger sizes and welding ranges that can be used with the

Ranger

250 GXT are shown in the following table:

The Ranger

Diameter Wire Speed Approximate

(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

“MIG” welding (GMAW - gas metal arc welding). The recommended electrodes are .030” and .035” L-50 and L-56. They must be used with a blended shielding gas such as C25 (75% Argon - 25% CO

welding ranges that can be used with the Ranger GXT are shown in the following table:

Diameter Wire Speed Approximate

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

electrode recommended for use with

250 GXT is NR®-211-MP. The electrode

250 GXT is recommended for limited

). The

250

TIG (CONSTANT CURRENT) WELDING

The Ranger®250 GXT 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 pro-

vides high frequency and shielding gas control for AC and DC

ARC GOUGING

The Ranger gouging.

GTAW (TIG) welding processes. The TIG Module allows full range output control. When using the Ranger

250 GXT for AC TIG welding of alu-

minum the following settings and electrodes are recommended: For AC TIG Welding, the maximum TIG Welding out-

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

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:

ELECTRODE SETTING CURRENT RANGE (DC, electrode positive)

RANGER®250 GXT

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

250 GXT can be used for limited arc

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

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

C-1

OPTIONAL EQUIPMENT

GENERAL

ACCESSORIES

C-1

K802N Power Plug Kit

K1690-1 GFCI Receptacle Kit

K1898-1 Spark Arrester Kit

K886-2 Canvas Cover (Large)

K1737-1 All Terrain Undercarriage

K1770-1 Factory Undercarriage

K1745-1 Welding Gas Cylinder, LPG Tank Holder

K2635-1 Small Two-Wheel Road Trailer with Duo-Hitch

K2639-1 Fender and Light Kit

K2640-1 Cable Rack

TIG

K1783-4 PTA-26 TIG Torch (25 ft 2pc)

KP509 Parts Kit

K930-2 TIG Module

K936-3 Control Cable for TIG Module

K937-45 TIG Module Control Cable Extension

K963-3 Hand Amptrol™

K870 Foot Amptrol™

K938-1 Contactor Kit

K939-1 Docking Kit

RECOMMENDED EQUIPMENT

STICK

K704 Accessory Kit - 400 Amp

K875 Accessory Kit - 150 Amp

K857 Remote Output Control - 25 ft. (7.6 m)

K857-1 Remote Output Control - 100 ft. (30.5 m)

K2627-2 Remote Output Control with 120V AC Receptacles

RANGER®250 GXT

WIRE FEEDER

K2613-5 LN-25 PRO Wire Feeder Standard

K126-12 K126™ PRO Innershield® 350A FCAW-SS Welding Gun 15 ft 1/16-5/64

KP1697-068Drive Roll Kit .068 in (1.7 mm) Cored Wire

KP1697-5/64 Drive Roll Kit 5/64 in (2.0 mm) Solid/Cored Wire

C-2

ACCESSORIES

WIRE FEEDER

K2652-2-10-45 Magnum® PRO 350 Welding Gun Ready-Pak 15 ft. 035-5/64

KP1696-1 Drive Roll Kit Combination .035 in / .045 in Solid Wire

K2473-1 POWER MIG® 180C MIG Welder

K1816-1 Full-KVA Adapter Kit

SPOOL GUN

K2532-1 Magnum® 100SG Spool Gun, Air-Cooled

C-2

PLASMA CUTTER

K2807-1 Tomahawk® 625 Plasma Cutter

K1816-1 Full-KVA Adapter Kit

RANGER®250 GXT

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.

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.

• 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.

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

RANGER®250 GXT

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

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.

D-2

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

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

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.

MAINTENANCE

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.

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.

• 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.

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.

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

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

Oil Filter KOHLER 12 050 01

FRAM PH8172*

Air Filter KOHLER 47 083 03

KOHLER CH730

KOHLER 12 050 01

FRAM PH8172*

KOHLER 24 083 03

Element FRAM CA79

Air Filter KOHLER 24 083 02

KOHLER 24 083 05

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

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

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

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

F-1

Enhanced Diagram

DIAGRAMS

F-1

RANGER®250 GXT

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

Enhanced Diagram

DIAGRAMS

F-2

RANGER®250 GXT

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-3

DIAGRAMS

F-3

RANGER®250 GXT

F-4

RCU

KERS

DIMENSION PRINT

F-4

10.78

10.2

7.22

36.2

33.62

CODES.

M20512

ALL

29.88

MAT

CS MAY NOT

RCU CI

KE EA

APHI R

RONT

ITH OIL

FUEL TA

ITY

PTY

AND

OF GRA

E N

CENTER

IN ENGI

14.75

19.50

17.50

: CASE F E T

20.8

21.00

24.8

42.1

2.6

41.2

TRUCK / UNDERCARRIAGE MOUNTING HOLES

FOR CODES 11400, 11420, 11493, 11667, 11668, 11736, 11737, 11792, 11793, 11799, 11800

RANGER®250 GXT

F-5

DIMENSION PRINT

F-5

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

M24957

NOTE: CASEFRONT GRAPHICS MAY NOT MATCH ALL CODES.

CENTER OF GRAVITY WITH OIL

IN ENGINE AND EMPTY FUEL TANK.

22.00

558.8

20.80

528.28

24.86

631.33

10.75

273.05

DIMENSION DIAGRAM CODES 12095, 12096

42.10

1069.46

2.6

66.55

19.50

495.3

17.50

444.5

41.20

1046.48

TRUCK/UNDERCARRIAGE MOUNTING HOL ES

RANGER®250 GXT

PARTS LIST FOR

Ranger

P-505P-505

GXT

250 GXT

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®GXT & RANGER®250 GXT

ILLUSTRATION OF SUB ASSEMBLIES

P-505-AP-505-A

RANGER

GXT & RANGER®250 GXT

08-03-2009

P-505-A.1P-505-A.1

Ranger®GXT & Ranger®250 GXT

For Codes 11154, 11269, 11400, 11420 & 11493

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

Optional Equipment

PAGE NO.

CODE NO.

11154 (GXT) 111111111

11269 (250 GXT) 112221111

11400 (250 GXT) 112232112

P-505-B.1

Miscellaneous Items

P-505-B.2

Case Front Assembly

P-505-C

Control Panel Assembly

P-505-D

Base/Fuel Tank/Battery

P-505-E

Assembly

Engine Assembly

P-505-F

Blower Baffle Assembly

P-505-G

Stator/Rotor Assembly

P-505-H

Covers & Case Back Assembly

P-505-J

11420 (250 GXT) 112222112

11493 (250 GXT) 112231113

RANGER

GXT & RANGER®250 GXT

08-03-2009

OPTIONAL EQUIPMENT LISTING

Miscellaneous Options Available for your machine are listed below:

# Indicates a change this printing.

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PART NUMBER

Accessory Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K702

Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1898-1

Canvas Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K886-2

Aux. Power Plug Kit (20 Amp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K802N

Aux. Power Plug Kit (15 Amp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K802R

4-Wire Grounding Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order T12153-9

GFCI Receptacle Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1690-1

Remote Output Control (25 Ft.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K857

Remote Output Control (100 Ft.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K857-1

Undercarriage (All Terrain) (See P-424) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1737-1

Undercarriage (Factory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1770-1

Cable Carrier Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1739-1

Single Cylinder Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1745-1

Small Welder Trailer, Heavy Duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2635-1

Rotor Pulling Kit (Available to Field Service Shops Only) . . . . . . . . . . . . . . . . . . . . . .Order S20788

Roll Cage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1788-1

Full KVA Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1816-1

P-505-B.1P-505-B.1

RANGER

GXT & RANGER®250 GXT

08-03-2009

P-505-B.2

MISCELLANEOUS ITEMS

(THESE ITEMS ARE NOT ILLUSTRATED)

P-505-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

Harness Assembly G4810 1 X Spark Arrestor S20462 1 X Plug & Lead Assembly S18250-889 1 X

RANGER

GXT & RANGER®250 GXT

08-03-2009

Case Front Assembly

15A

19B

19A

19C

16A

16B

P-505-CP-505-C

15A

16A

16B

19B

19A

19C

RANGER

GXT & RANGER®250 GXT

10-04-2011

P-505-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

1 Case Front G3860-4 1 X • 1 Case Front G3860-8 1 • X 3A Output Terminal Assembly, Includes: (1/2 Per Asbly) T14166-9 2 X X 3B Output Stud Nut T3960 2 X X 3C 1/2-13 x .75 HHCS CF000020 2 X X 3D Self Tapping Screw (Not Shown) S8025-91 4 X X 4 Circuit Breaker Cover M19161 1 X • 5 Receptacle Cover M18861 1 X X 6A Receptacle, Single S18907-2 1 X X 6B Lock Washer T9695-3 4 X X 6C #8-32 HN CF000042 4 X X 6D #8-32 x .625 Fillister Screw NSS 4XX 7 Receptacle, Gasket S21088 2 X X 8 Receptacle Cover M16996 1 X X 9A Receptacle, Duplex S20184 2 X X 9B Thread Forming Screw (Cutting) S9225-63 4 X X 9C Speed Nut, #10-24 T11525-1 4 X X 10 Lock Nut T9187-1 1 X X 11 1/4-20 HN CF000017 1 X X 12 Rating Plate L12383 1 X • 12 Rating Plate L12790 1 • X 13 Button, Fastener T14659-1 2 X X 14 Circuit Breaker Decal S24672-7 1 X • 15 Toggle Switch, DPDT (Local/Remote) T10800-39 1 X X 15A Adapter Plate S25928 1 X X 15B Self Tapping Screw S8025-98 2 X X 15C Sealing Boot (Not Shown) S22061-4 1 • X 16A Connector Cap S17062-2 1 X X 16B Self Tapping Screw S8025-96 4 X X 17 Amphenol Bypass PCB Assembly M20463-[ ] 1 X X 18 Bypass Assembly (Not Shown) S24982 1 X X 19A Output Stud Cover M20007 2 • X 19B Output Stud Cover Plate S25669 2 • X 19C Thread Forming Screw S9225-68 4 • 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.

NSS - Not Sold Separately

RANGER

GXT & RANGER®250 GXT

01-22-2010

Control Panel Assembly

20A

22B

{

18A

18B

18C

23A

22A

23B

19A

19B

18C

18D

18E

P-505-DP-505-D

20A

18C

18B 18A

22B

19B

19A

18E

18C

18D

22A

23A

23B

RANGER

GXT & RANGER®250 GXT

08-03-2009

P-505-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

1A Top Bezel G3593 1 X X 1B Self Tapping Screw S24738-1 7 X X 2A Right Bezel G3594-1 1 X X 2B Self Tapping Screw S24738-1 2 X X 3A Left Bezel G3594-2 1 X X 3B Self Tapping Screw (Not Shown) S24738-1 2 X X 4 Choke Control S7525-21 1 X X 5 Engine Switch S25686 1 X X 5A Engine Switch Handle S25718 1 X X 6 Hour Meter-Miniature S17475-3 1 X X 7A Circuit Breaker - 50A, 250 VAC T12287-19 2 X • 7B #10-32 .375 RHS (Not Shown) CF000113 2 X • 7C Lock Washer (Not Shown) E106A-1 2 X • 7D Plain Washer (Not Shown) S9262-126 8 X • 8 Circuit Breaker - 20A, 250 VAC, 50 VDC T12287-38 2 X • 9 Circuit Breaker - 25A, 250 VAC, 24 VDC T12287-21 1 X • 10 Knob T10491-1 1 X X

11 Nameplate - Ranger

GXT G4819 1 X • 11 Nameplate - Ranger®250 GXT G4819-1 1 • X 12 “O” Ring T13483-7 1 X X 17 Fuel Gauge S17585-1 1 X X 18A Thread Forming Screw (Per Assembly) S9225-76 1 X X 18B Lock Washer (Per Assembly) E106A-1 1 X X 18C Plain Washer (Per Assembly) S9262-27 2 X X 18D Lock Washer (Per Assembly) T9695-1 1 X X 18E 1/4-20 HN (Per Assembly) CF000017 1 X X 19A Potentiometer (10K) T10812-112 1 X X 19B Potentiometer Spacer S18280 1 X X 20 Selector Switch & Mounting Assembly M17013-3 1 X X 20A Control Handle M16493 2 X X 20B Self Tapping Screw (Not Shown) S8025-78 2 X X 21 Arc Polarity Switch Assembly M17014-1 1 X X 21A Lock Nut (Not Shown) T9187-9 4 X X 22A Circuit Breaker - 20A, 250VAC, 50VDC T12287-38 3 • X 22B Sealing Boot S22061-2 3 • X 23A Circuit Breaker - 50A, 2 Pole, Includes (23B) M20585 1 • X 23B Circuit Breaker Cover Seal S24911-2 1 • X 23C Sems Screw (Not Shown) T10082-30 4 • X 23D Lock Washer (Not Shown) T4291-A 4 • X

RANGER

GXT & RANGER®250 GXT

08-03-2009

Base/Fuel Tank/Battery Assembly

12A

11A

13A

{

10B

10A

10B

10A

P-505-EP-505-E

12A

13A

RANGER

11A

GXT & RANGER®250 GXT

08-03-2009

P-505-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 1 X X X 2A Engine Cross Support L11147 1 X X X 2B Thread Forming Screw (Cutting) S9225-68 8 X X X 4 Fuel Tank & Assembly, Includes: L12164-1 1 X X X 4A Fuel Tank NSS 1 XXX 4B Fuel Sender M20302 1 X X X 4D Fuel Pick-Up Tube Assembly S19565-4 1 X X X 4E Rubber Plug S19563 1 X X X 4F Fuel Cap S20541 1 X X X 4G Hose Clamp T13777-7 2 X • X 4H Flex Tube T10642-274 1 X • • 4H Flex Tube T10642-275 1 • • X 5 Stator Support Bracket L12329 1 X X X 5A Rubber Mounting S24344 2 X X X 5B 3/8-16 x 2.50 HHB CF000196 2 X X X 5C Plain Washer S9262-113 8 X X X 5D 3/8-16 HN CF000067 4 X X X 6A Battery Bracket S22018 1 X X X 6B Carriage Bolt T11827-45 2 X X X 6C Lock Washer E106A-2 2 X X X 6D 1/4-20 HN CF000017 2 X X X 7 12 Volt Storage Battery (M9399-13) NSS 1 XXX 8A Battery Tray L10955 1 X X X 8B Thread Forming Screw (Cutting) S9225-68 3 X X X 8C Support M16528 2 X X X 9A Battery Cable (Neg.) (Not Shown) S8070-28 1 X X X 9B Battery Cable (Pos.) (Not Shown) S8070-11 1 X X X 10A Fuel Tank Brace G4003-1 1 X X X 10B Thread Forming Screw S9225-68 2 X X X 11 Reactor Assembly L12326 1 X X X 11A Self Tapping Screw S8025-78 4 X X X 12A Electric Fuel Pump M20393 1 • X • 12B Fuel Pump Bracket (Not Shown) S25778 1 • X • 12C Thread Forming Screw (Not Shown) S9225-68 4 • X • 12D Plain Washer (Not Shown) S9262-98 2 • X • 12E Flex Tube (Not Shown) T10642-275 2 • X • 12F Hose Clamp (Not Shown) T13777-7 4 • X • 13A Choke Coil & Lamination Assembly L9036-1 1 X X X 13B 3/8-16 x 1.50 HHCS (Not Shown) CF000066 2 X X X 13C Lock Washer (Not Shown) E106A-16 4 X X X 13D 3/8-16 HN (Not Shown) CF000067 2 X X X 13E Plain Washer (Not Shown) S9262-120 2 X X X

NSS - Not Sold Separately

RANGER

GXT & RANGER®250 GXT

08-03-2009

Engine Assembly

Supplied with

Engine

Supplied with Engine

P-505-FP-505-F

Supplied with Engine

Supplied with

Engine

RANGER

GXT & RANGER®250 GXT

08-03-2009

P-505-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

1 Engine (M19590) - Kohler NSS 1X• 1 Engine (M21300) - Kohler NSS 1•X 1A Rubber Mounting S24344 2 X X 1B 3/8-16 x 3.00 HHCS CF000039 2 X X 1C Plain Washer S9262-113 6 X X 1D Lock Washer E106A-16 2 X X 1E Plain Washer (Not Shown) S9262-120 2 X X 1F 3/8-16 HN (Not Shown) CF000067 2 X X 2 Muffler Assembly (Kohler) G3574-4 1 X X 2A Exhaust Gasket (Supplied w/Engine) M16999-1 2 X X 2B Hardware for Muffler

(Supplied w/Engine)

(Not Shown) NSS 2XX

4 Oil Drain Valve S24662 1 X X 5A Output Pipe (Not Shown) M16980-1 1 X X 5B Spark Arrestor Clamp (Not Shown) S20462 1 X X 6 Engine Seal (Not Shown) S22415-7 1 X X

NSS - Not Sold Separately

RANGER

GXT & RANGER®250 GXT

08-03-2009

Blower Baffle Assembly

P-505-GP-505-G

RANGER

GXT & RANGER®250 GXT

08-03-2009

P-505-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 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 T14614-1 1 X 16 Grommet S18543-1 1 X 17 Thread Forming Screw (Cutting) S9225-68 1 X

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

RANGER

GXT & RANGER®250 GXT

08-03-2009

Stator/Rotor Assembly

7A 7B

}

P-505-HP-505-H

7A 7B

RANGER®GXT & RANGER®250 GXT

08-03-2009

P-505-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

1 Rotor & Shaft Assembly L10825 1 X 1A Bearing M9300-85 1 X 1B Special Hex Head Bolt T14843-3 1 X 1C Plain Washer S9262-149 1 X 1D Blower L9033 1 X 1E Tolerance Ring S18044-9 1 X 1F Centering Washer (Not Shown) S20110-3 1 X 4A Firewall G3849 1 X 4B Bushing T12380-1 3 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 S8025-91 2 X 5D 1/4-20 x 1.00 HHCS CF000015 2 X 5E Lock Washer E106A-2 2 X 5F 1/4-10 HN CF000017 2 X 6A Rubber Mounting S24344 2 X 6B 3/8-16 x 2.50 HHB CF000196 2 X 6C Plain Washer S9262-113 6 X 6D 3/8-16 HN CF000067 4 X 7 Stator Frame Assembly, Includes: G2618-7 1 X 7A 3/8-16 HN CF000067 2 X 7B Lock Washer E106A-16 2 X 7C Plain Washer S9262-120 2 X 8 Solenoid Assembly S20752 1 X 8A Self Tapping Screw S8025-91 3 X 9 Pull Wire S20848 1 X 9A Bracket (Not Shown) S21177 1 X 9B 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

RANGER

GXT & RANGER®250 GXT

08-03-2009

Covers & Case Back Assembly

23A

P-505-JP-505-J

23A

RANGER

GXT & RANGER®250 GXT

08-03-2009

P-505-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 X X • 1A Case Side - Right G3510-1 1 • • X 1B Thread Forming Screw (Cutting) (Not Shown) S9225-68 3 X X • 1B Thread Forming Screw (Cutting) (SS) (Not Shown) S24739-27 3 • • X 2A Case Side - Left G3511 1 X X • 2A Case Side - Left G3511-1 1 • • X 2B Thread Forming Screw (Cutting) S9225-68 3 X X • 2B Thread Forming Screw (Cutting) (SS) (Not Shown) S24739-27 3 • • X 3A Case Back G3865 1 X X X 3B Thread Forming Screw (Cutting) (Not Shown) S9225-68 4 X X X 4A Roof G3882-4 1 X X • 4A Roof G3882-5 1 • • X 4B Thread Forming Screw (Cutting) S9225-68 16 X X • 4B Thread Forming Screw (Cutting) (SS) S24739-27 16 • • X 4C Door Bumper (Not Shown) T14882-1 2 X X X 5A Left Engine Cover L11529-1 1 X X • 5A Left Engine Cover L11529-3 1 • • X 5B Thread Forming Screw (Cutting) (Not Shown) S9225-66 1 X X • 5B Thread Forming Screw (Cutting) (Not Shown) S24739-31 1 • • X 5C Speed Nut (Not Shown) T11525-5 1 X X X 6A Right Engine Cover, Includes: L11528 1 X X • 6A Right Engine Cover, Includes: L11528-1 1 • • X 6B Latch S24694 1 X X X 6C Hinge S24348 2 X X X 6E Rivet (Not Shown) T12584-12 6 X X X 6F Oil Drain Decal (Not Shown) S24665 1 X X X 7 Fuel Trough L12084 1 X X X 8 Cover Seal S12934 1 X • X 8 Cover Seal S12934-1 1 • X • 9A Engine Top Cover Welded Assembly G3514 1 X X • 9A Engine Top Cover Welded Assembly G3514-1 1 • • X 9B Latch S24694 1 X X X 9D Door Bumper (Not Shown) T14882 2 X X X 9E Rivet (Not Shown) T12584-6 4 X X X 9F Rivet (Not Shown) T12584-9 4 X X X 10 Battery Caution Decal S17851 1 X X X 11 Warning Label M16197 1 X X X 12 Fuel Warning Decal T13086-108 1 X X X 13 Wiring Diagram M20443 1 X X X 14 Warranty Decal Part of L12383 1 X X X 15 Logo Decal S11893-7 2 X X X 16 Engine Decal S24323 1 X • X 16 Engine Decal S26884 1 • X • 17 Oil Drain Decal S24665 1 X X X 21 Hinge Assembly (Right Side) S24295-1 2 X X X 23 Airbox G3869-2 1 X X X 23A Engine Seal S22415-7 1 X X X 23B Thread Forming Screw (Cutting) (Not Shown) S9225-68 10 X X X 24 Flex Tube (Not Shown) T10642-242 1 X X X

# # # # # #

RANGER

GXT & RANGER®250 GXT

02-09-2012

NOTES

RANGER®GXT & RANGER®250 GXT

PARTS LIST FOR

Ranger

P-634P-634

250 GXT

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

ILLUSTRATION OF SUB ASSEMBLIES

P-634-AP-634-A

RANGER

250 GXT

Oct-13

P-634-A.1P-634-A.1

Ranger®250 GXT

For Codes: 11667, 11668, 11736, 11737, 11792, 11793,

11799, 11800, 12095, 12096, 12201 & 12202

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.

11667 11111111

11668 11111112

11736 11111113

P-634-B.2

Case Front (Upper)

P-634-C

Case Front (Lower)

P-634-D

Base/Fuel Tank/Battery

P-634-E

Assembly

Engine Assembly

P-634-F

Blower Baffle Assembly

P-634-G

Stator/Rotor Assembly

P-634-H

Covers & Case Back Assembly

P-634-J

11737 11111114

11792 11122113

11793 11122114

11799 11132114

11800 11132114

12095 11143115

12096 11143116

RANGER

250 GXT

Oct-13

P-634-A.2P-634-A.2

Ranger®250 GXT

For Codes: 11667, 11668, 11736, 11737, 11792, 11793,

11799, 11800, 12095, 12096, 12201 & 12202

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.

12201 11153115

12202 11153116

P-634-B.2

Case Front (Upper)

P-634-C

Case Front (Lower)

P-634-D

Base/Fuel Tank/Battery

P-634-E

Assembly

Engine Assembly

P-634-F

Blower Baffle Assembly

P-634-G

Stator/Rotor Assembly

P-634-H

Covers & Case Back Assembly

P-634-J

RANGER

250 GXT

Oct-13

P-634-B.2

MISCELLANEOUS ITEMS

(THESE ITEMS ARE NOT ILLUSTRATED)

P-634-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

Oct-13

Case Front (Upper)

58A

25A

25B

57A

59A

58A

P-634-CP-634-C

58A

25B

57A

25A

59A

RANGER

250 GXT

Oct-13

P-634-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

1 Case Front Assembly (G3666-48), Includes: NSS 1X 1A Case Front G3860-12 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 G6782-1

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 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 60 Hang Tag (Not Shown) L15174 1 X

NSS - Not Sold Separately

RANGER

250 GXT

Oct-13

Case Front (Lower)

51A

18B

15A

18A

25A

34A

27A

18C

11A

11B

51B

P-634-DP-634-D

18B

15A

51B

51A

34A

18C

18A

27A

11B

25A

11A

RANGER

250 GXT

Oct-13

P-634-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: (1/2 Per Asbly) T14166-9 2 X 6B Output Stud Nut T3960 2 X 6C Self Tapping Screw S8025-91 4 X 6D 1/2-13 x .875 HHCS CF000344 2 X 6E Plain Washer S9262-1 2 X 6F Lock Washer E106A-15 2 X 11A Circuit Breaker (50 Amp) 250VAC 50VDC M20585 1 X 11B Circuit Breaker Cover Seal S24911-2 1 X 11C Sems Screw (Not Shown) T10082-30 4 X 11D Lock Washer (Not Shown) T4291-A 4 X 12 Circuit Breaker (20 Amp) 250VAC, 50VDC T12287-38 3 X 13 Sealing Boot S22061-2 3 X 14 Receptacle Cover M18861 1 X 15A Receptacle, Single S18907-2 1 X 15B Lock Washer (Not Shown) T9695-3 4 X 15C #8-32 HN (Not Shown) CF000042 4 X 16 Receptacle, Gasket S21088 2 X 17 Receptacle Cover M16996 1 X 18A Receptacle, Duplex S20184 2 X 18B Thread Forming Screw S9225-63 4 X 18C Speed Nut, #10-24 T11525-1 4 X 19 1/4-20 HJLN T9187-1 1 X 20 1/4-20 HN CF000017 1 X 22 Rating Plate L12790 1 X 25A Toggle Switch (Part of G4810-4 Harness) T10800-39 1 X 27A Adapter Plate S25928 1 X 27B Self Tapping Screw (Not Shown) S8025-98 2 X 28 Self Tapping Screw S8025-96 2 X 31 Connector Cap S17062-10 1 X 34A RF Bypass Filter Assembly S24982 1 X 34B Plain Washer (Not Shown) S9262-27 1 X 34C Lock Washer (Not Shown) E106A-1 1 X 34D #10-24 HN (Not Shown) CF000010 1 X 35 Amphenol Bypass PC Board Assembly M20463-[ ] 1 X 36 Sealing Boot S22061-4 1 X 51A Output Stud Cover Plate S25669 2 X 51B Thread Forming Screw S9225-66 4 X 56 Output Stud Cover M20007 2 X

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

RANGER

250 GXT

Oct-13

Base/Fuel Tank/Battery Assembly

11A

13A

8D 8E

17A

17G

17F

17H

17E

17C

17B

17D

P-634-EP-634-E

11A

17G

17F

17H

17B

17A

17E

17C

17D

13A

RANGER

250 GXT

Oct-13

P-634-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 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) S9225-68 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 20 EPA Compliance Decal NSS 1 • XXXX 25 Flex Tube (Not Shown) (Fuel Tank Vent Hose) T10642-321 1 X • X X X 25 Flex Tube (Not Shown) (Fuel Tank Vent Hose) T10642-339 1 • X • • •

NSS - Not Sold Separately

RANGER

250 GXT

Oct-13

Engine Assembly

P-634-FP-634-F

RANGER

250 GXT

Oct-13

P-634-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 Output Pipe Elbow (Not Shown) M16980-1 1 X X X

NSS - Not Sold Separately

RANGER

250 GXT

Oct-13

Blower Baffle Assembly

P-634-GP-634-G

RANGER

250 GXT

Oct-13

P-634-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 3 X 17 Thread Forming Screw S9225-68 2 X

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

RANGER

250 GXT

Oct-13

Stator/Rotor Assembly

15A

P-634-HP-634-H

15A

RANGER®250 GXT

Oct-13

P-634-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)

T10642-242 1 X

RANGER

250 GXT

Oct-13

Covers & Case Back Assembly

21A

25A

25B

P-634-JP-634-J

25A

25B

RANGER

21A

250 GXT

Oct-13

P-634-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 X • X • X • 1A Case Side - Right G3510-1 1 • X • X • X 1B Thread Forming Screw (Not Shown) S9225-68 3 XXXXXX 2A Case Side - Left G3511 1 X • X • X • 2A Case Side - Left G3511-1 1 • X • X • X 2B Thread Forming Screw (Not Shown) S9225-68 3 XXXXXX 3A Case Back (Includes Item 23) G3865-4 1 XXXXXX 3B Thread Forming Screw (Not Shown) S9225-68 4 XXXXXX 3C Fastener Button (Not Shown) T14659-1 2 XXXXXX 4A Roof G3882-4 1 X ••••• 4A Roof G3882-5 1 • X •••• 4A Roof G3882-6 1 • • X • X • 4A Roof G3882-8 1 •••X•X 4B Thread Forming Screw S9225-68 16 XXXXXX 4C Door Bumper (Not Shown) T14882-1 6 XXXXXX 5A Left Engine Cover L11529-1 1 X • X • X • 5A Left Engine Cover L11529-3 1 • X • X • X 5B Thread Forming Screw (Not Shown) S9225-66 1 XXXXXX 5C Speed Nut (Not Shown) T11525-5 1 XXXXXX 6A Right Engine Cover, Includes: L11528 1 X • X • X • 6A Right Engine Cover, Includes: L11528-1 1 • X • X • X 6B Latch S24694 1 XXXXXX 6C Hinge S24348 2 XXXXXX 6D Rivet (Not Shown) T12584-12 6 XXXXXX 6E Oil Drain Decal (Not Shown) S24665 6 XXXXXX 7 Fuel Trough L12084 1 XXXXXX 8 Cover Seal S12934-1 1 XXXXXX 9A Engine Top Cover Welded Assembly G3514 1 X ••••• 9A Engine Top Cover Welded Assembly G3514-1 1 • X •••• 9A Engine Top Cover Welded Assembly G3514-2 1 • • X • X • 9A Engine Top Cover Welded Assembly G3514-3 1 •••X•X 9B Latch S24694 1 XXXXXX 9C Door Bumper (Not Shown) T14882 2 XXXXXX 9D Rivet (Not Shown) T12584-6 4 XXXXXX 9E Rivet (Not Shown) T12584-9 4 XXXXXX 9E Rivet (Not Shown) (Codes 11792 & 11793) T12584-12 4 • • X • • • 10 Battery Caution Decal S17851 1 XXXXXX 11 Warning Label M16197 1 XXXXXX 12 Fuel Warning Decal T13086-108 1 XXXXXX 13 Wiring Diagram M22385 1 XXXXXX 14 Warranty Decal Part of L12790 1 XXXXXX 15 Logo Decal S27368-5 2 XXXXXX 16 Engine Decal S26884 1 XXXX• • 16 Engine Service Decal S29943 1 ••••XX 17 Oil Drain Decal S24665 1 XXXXXX 18 Warning Decal S25896 1 XXXXXX 19 CO Warning Decal M21436 1 XXXXXX 20 Family Decal M21952-1 2 XXXXXX 21A Hinge Assembly (Right Side) S24295-2 2 XXXXXX 21B Rivet (Not Shown) T12584-9 4 XXXXXX 21B Rivet (Not Shown) (Codes 11792 & 11793) T12584-12 4 • • X • • •

RANGER

250 GXT

Oct-13

P-634-J.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

23 Foam Airbox M22367 1 XXXXXX 25A Battery Cover M22185 1 XXXXXX 25B Thread Forming Screw S9225-68 3 XXXXXX 26 Fuel Filling Warning Decal (Not Shown) T13086-215 1 XXXXXX

RANGER

250 GXT

Oct-13

NOTES

RANGER®250 GXT

CUSTOMER ASSISTANCE POLICY

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.

Lincoln Electric IM921 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual