Lincoln Electric SVM150-A User Manual

SVM150-A

September, 2002

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
CONT AINED THROUGHOUT .

And, most importantly, think
before you act and be careful.

SERVICE MANUAL

For use with machines having Code Numbers: 10654

Ranger 250

TM

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

View Safety Info View Safety Info View Safety Info View Safety Info

RETURN TO MAIN INDEX

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Copyright © 2002 Lincoln Global Inc.

SAFETY

i i

RANGER 250

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 weld-

ing 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.

____________________________________________________

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.

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.

WARNING

Mar ‘95

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

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.

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

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.

The Above For Diesel Engines

The Above For Gasoline Engines

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

SAFETY

ii ii

RANGER 250

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.

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
between the 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.

3.j. Also see Items 6.c. and 8.

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 below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon

vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors

to
form phosgene, a highly toxic gas, and other irritating
products.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

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

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

5.e. Also see item 1.b.

Mar ‘95

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

RANGER 250

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.

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

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.

iii

SAFETY

iii

Mar ‘95

WELDING 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.

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

SAFETY

iv iv

RANGER 250

PRÉCAUTIONS DE SÛRETÉ

Pour

votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc­tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud­er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soud

e pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSAStandard
W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

v v

RANGER 250

Page

Safety.................................................................................................................................................i-iv

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

Technical Specifications..............................................................................................................A-2

Safety Precautions......................................................................................................................A-3

Location and Ventilation..............................................................................................................A-3

Pre-Operation Engine Service ....................................................................................................A-4

Electrical Output Connections.....................................................................................................A-5

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

Safety Instructions.......................................................................................................................B-2

General Description ....................................................................................................................B-2

Design Features ..........................................................................................................................B-3

Controls and Settings..................................................................................................................B-3

Engine Operation........................................................................................................................B-5

Welder Operation........................................................................................................................B-7

Auxiliary Power ...........................................................................................................................B-9

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

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

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair................................................................................................Section F

Electrical Diagrams..............................................................................................................Section G

Parts Manual ................................................................................................................................P-358

RETURN TO MAIN INDEX

TABLE OF CONTENTS

- INSTALLATION SECTION -

Section A-1 Section A-1

RANGER 250

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

Technical Specifications..............................................................................................................A-2

Safety Precautions......................................................................................................................A-3

Location and Ventilation..............................................................................................................A-3

Storing ..................................................................................................................................A-3

Stacking................................................................................................................................A-3

Angle of Operation................................................................................................................A-3

Lifting....................................................................................................................................A-3

Additional Safety Precautions.....................................................................................................A-4

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

High Temperature Operation ................................................................................................A-4

Towing...................................................................................................................................A-4

Pre-Operation Engine Service ....................................................................................................A-4

Oil .........................................................................................................................................A-4

Fuel.......................................................................................................................................A-4

Engine Cooling System........................................................................................................A-4

Battery Connections .............................................................................................................A-5

Muffler Outlet Pipe ............................................................................................................ ....A-5

Spark Arrester.......................................................................................................................A-5

High Frequency Generators for TIG Applications.................................................................A-5

Remote Control.....................................................................................................................A-5

Welding Terminals ................................................................................................................A-5

Electrical Output Connections.....................................................................................................A-5

Machine Grounding ..............................................................................................................A-5

Welding Output Cables.........................................................................................................A-6

Cable Installation ............................................................................................................A-7

Auxiliary Power Receptacles................................................................................................A-7

Standby Power Connections................................................................................................A-7

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

INSTALLATION

A-2 A-2

RANGER 250

Onan P216
(K1725-1)

Kohler CH20
(K1725-2)

2 cylinder

16 HP @

3600 RPM

(Onan)

20 HP @

3600 RPM

(Kohler)

High Idle 3700

Full Load 3500

Low Idle 2400

44 (714) - Onan

38 (624) - Kohler

Bore x Stroke inch

(mm)

3.25 x 2.625

(83 x 67) (Onan)

3.03 x 2.64

(77 x 67) (Kohler)

12 VDC Battery &
Starter

(Group 58; 435 cold
crank amps)

Battery Charger

20 A. regulated (K1725-1)
15 A. regulated (K1725-2)

(Push Button Start)

Fuel: 12 gal.

45.4 L
Oil: 1.8 Qts.

1.7 L (Onan)
Oil: 2.0 Qts.

1.9 L (Kohler)
Cooling System:

Air-Cooled

TECHNICAL SPECIFICATIONS - RANGER 250 (K1725-1/K1725-2)

INPUT - GASOLINE ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

cu. in. (cu. cm.) System

RATED OUTPUT - WELDER

Welding Output Volts at Rated Amps Duty Cycle Max. OCV @ 3700 RPM

CC STICK & PIPE DC Output 25 Volts at 250 Amps 100%
STICK / PIPE Output Range 20 to 250 Amps
TIG Output Range 20 to 250 Amps 80 Volts
CV WIRE DC Output 25 Volts at 250 Amps 100%
CV WIRE Output Range 14 to 28 Volts

OUTPUT - GENERATOR

Auxiliary Power

1

8,000 Watts, 60 Hz

120/240 Volts

100% Duty Cycle

PHYSICAL DIMENSIONS

Height Width Depth Weight

30.00* in. 21.50 in. 42.25 in. 452 lbs. (205 kg.) K1725-1

762.0 mm 546.0 mm 1073.0 mm 434 lbs. (197 kg.) K1725-2

* Top of enclosure, add 6.0” (152 mm) for exhaust

ENGINE COMPONENTS

Lubrication Valve Lifters Fuel System Governor

Full Pressure Solid (Onan) Vacuum Pulse Pump (Onan) Mechanical Governor
with Full Flow Filter Hydraulic (Kohler) Mechanical Fuel Pump (Kohler) 5% Regulation

Air Cleaner Engine Idler Muffler Engine Protection

Duel Element Automatic Idler Low noise muffler: Top outlet Shutdown on low oil

can be rotated. Made from pressure.
long life, aluminized steel.

Receptacles Auxiliary Power Circuit Breaker Other Circuit Breakers

Two 120 VAC Duplex Two 20 Amp for Two Duplex 25 Amp for Battery Charging
(5-20R) Receptacle Circuit

One 120/240 VAC Dual Two 35 Amp for Dual Voltage 150 Amp for 42 Volt Wire Feeder
Voltage Power

Full KVA (14-50R)

1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ±10% at all loads up to rated capacity. When welding,
available auxiliary power will be reduced.

Read this entire installation section before you
start installation.

SAFETY PRECAUTIONS

Do not attempt to use this equipment until you have
thoroughly read the engine manufacturer’s manual
supplied with your welder. It includes important safety
precautions, detailed engine starting, operating and
maintenance instructions and parts lists.

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and
ground.

• Always wear dry insulating
gloves.

ENGINE EXHAUST can kill.

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

• Do not stack anything near the
engine.

MOVING PARTS can injure.

• Do not operate with doors open
or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

See additional safety information at the front of this
manual.

Only qualified personnel should install, use, or
service this equipment.

LOCATION AND VENTILATION

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

STORING

1. Store the machine in a cool, dry place when it is
not in use. Protect it from dust and dirt. Keep it
where it can’t be accidentally damaged from con­struction activities, moving vehicles, and other haz­ards.

2. If you will be storing the machine for over 30 days,
you should drain the fuel to protect fuel system and
carburetor parts from gum deposits. Empty all fuel
from the tank and run the engine until it stops from
lack of fuel. If you prefer, you can treat the gaso­line with a stabilizer to prevent deterioration rather
than drain the system. Follow the stabilizer manu­facturer’s instructions. Add the correct amount of
stabilizer for the size of the fuel tank. Fill the tank
with clean, fresh gasoline. Run the engine for two
to three minutes to circulate the stabilizer through
the carburetor.

3. While the engine is still warm, drain the oil and refill
with fresh 10W30 oil. Change the oil filter.

4. Remove the spark plugs and add one to two table­spoons of engine oil or rust inhibitor into each cylin­der. Replace the spark plugs but do not connect
the plug leads. Crank the engine two or three
times to distribute the oil.

5. Clean any dirt or debris from the cylinder and cylin­der head fins and other exterior surfaces.

STACKING

Ranger 250 machines CANNOT be stacked.

ANGLE OF OPERATION

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

When operating the welder at an angle, the effective
fuel capacity will be slightly less than the specified 12
gallons (45.4 liters).

LIFTING

The Ranger 250 weighs approximately 452 lbs./205 kg.
with a full tank of gasoline. A lift bail is mounted to the
machine and should always be used when lifting it.

INSTALLATION

A-3 A-3

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

WARNING

ADDITIONAL SAFETY PRECAUTIONS

FALLING EQUIPMENT can cause
injury.

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

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

HIGH ALTITUDE OPERATION

At higher altitudes, output de-rating may be necessary.
For maximum rating, de-rate the welder output 3.5%
for every 1000 ft. (305m). Contact an authorized
engine service shop for modifications to operate above
5,000 ft. (1525m).

HIGH TEMPERATURE OPERATION

At temperatures above 30°C, output de-rating is nec­essary. For maximum output ratings, de-rate the
welder output 5% for every 10°C above 30°C.

TOWING

The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle1is
Lincoln’s 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.

2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.

3. Proper placement of the equipment on the trailer to
insure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.

4. Typical conditions of use such as travel speed,
roughness of surface on which the trailer will be
operated, environmental conditions, and likely
maintenance.

5. Conformance with federal, state and local laws.

1

1

Consult applicable federal, state and local laws regarding specific
requirements for use on public highways.

PRE-OPERATION ENGINE SERVICE

Read and understand the information about the gaso­line engine in the Operation and Maintenance sec­tions of this manual before you operate the Ranger

250.

• Keep hands away from the engine muffler or HOT
engine parts.

• Stop the engine and allow it to cool before fueling.

• Do not smoke when fueling.

• Fill the fuel tank at a moderate rate and do not over­fill.

• Wipe up spilled fuel and allow the fumes to clear
before starting the engine.

• Keep sparks and flame away from the fuel tank.

• Remove the fuel cap slowly to release pressure.

OIL

The Ranger 250 is shipped with the engine

crankcase filled with high quality SAE 10W­30 oil (API class CD or better). CHECK THE OIL
LEVEL BEFORE YOU START THE ENGINE. If it is
not up to the FULL mark on the dipstick, add oil as
required. Check the oil every four hours of running
time during the first 25 running hours. Refer to the
engine operator’s manual for specific oil recommenda­tions and break-in information. The oil change interval
is dependent on the quality of the oil and the operating
environment. Refer to the engine operator’s manual
for the proper service and maintenance intervals.

FUEL

Use gasoline fuel only.

Fill the fuel tank with clean, fresh fuel. The
capacity of the fuel tank is 12 gallons (45.4
liters).

NOTE: The fuel tank is mounted below the engine, so
a fuel shutoff valve is not required.

ENGINE COOLING SYSTEM

Air to cool the engine is drawn in through the lower set
of louvers on the case back. It is important that the
intake air is not restricted. Allow a minimum clearance
of 2 feet (0.6m) from the case back to a vertical sur­face.

INSTALLATION

A-4 A-4

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

WARNING

WARNING

BATTERY CONNECTIONS

BATTERY ACID CAN BURN EYES AND
SKIN.

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

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

The Ranger 250 is shipped with the negative battery
cable disconnected. Make certain that the RUN-STOP
switch is in the STOP position. Remove the screws
from the rear battery tray using a screwdriver or a 3/8"
socket. Attach the negative battery cable to the nega­tive battery terminal and tighten using a socket or
wrench.

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. See the battery charging
instructions in the Maintenance section.

MUFFLER OUTLET PIPE

Using the clamp provided, secure the outlet pipe to the
outlet tube with the pipe positioned to direct the ex­haust in the desired direction. Tighten using a socket or
wrench.

SPARK ARRESTER

Some federal, state or local laws may require spark
arresters in locations where unarrested sparks may
present a fire hazard. The standard muffler included
with this welder does not qualify as a spark arrester.
When required by local regulations, a suitable spark
arrester, such as the S24647, must be installed and
properly maintained. See the Accessories section for
more information.

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

HIGH FREQUENCY GENERATORS FOR
TIG APPLICATIONS

The K930-2 TIG Module is suitable for use with the
Ranger 250. The Ranger 250 and any high frequency
generating equipment must be properly grounded.
See the K930-2 operating manual for complete instruc­tions on installation, operation, and maintenance.

REMOTE CONTROL

The Ranger 250 is equipped with a 6-pin and a 14-pin
Amphenol connector. The 6-pin connector is for con­necting the K857 or K857-1 Remote Control (optional)
or for TIG welding, the K870 foot Amptrol or the K963­2 hand Amptrol.

When in the CC-STICK, PIPE, and CV-WIRE modes
and when a remote control is connected to the
Amphenol, the auto-sensing circuit in the Ranger 250
automatically switches the OUTPUT control from con­trol at the welder to remote control.

The 14-pin connector is used to directly connect a wire
feeder. In the CV-WIRE mode, the Ranger 250 auto­sensing circuit automatically makes the Ranger 250
OUTPUT control inactive and the wire feeder voltage
control active when the control cable is connected to
the 14-pin connector.

NOTE: When a wire feeder with a built in welding volt­age control is connected to the 14-pin connector, do
NOT connect anything to the 6-pin connector.

WELDING TERMINALS

The Ranger 250 is equipped with a toggle switch for
selecting “hot” welding terminals when in the “WELD
TERMINALS ON” position or “cold” welding terminals
when in the “REMOTELY CONTROLLED” position.

ELECTRICAL OUTPUT
CONNECTIONS

See Figure A.1 for the location of the 120 and 240 volt
receptacles, weld output terminals, and ground stud.

MACHINE GROUNDING

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

INSTALLATION

A-5 A-5

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

WARNING

CAUTION

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

a) Be grounded to the frame of the welder using a

grounded type plug.

b) Be double insulated.

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

When this welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame
of the vehicle. When connected to premises wiring
such as that in a home or shop, the welder frame must
be connected to the system earth ground. See further
connection instructions in the section entitled Standby
Power Connections as well as the article on ground­ing in the latest U.S. 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 U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding
stud marked with the ground symbol is provided
on the front of the welder.

WELDING OUTPUT CABLES

With the engine off, connect the electrode and work
cables to the output terminals. The welding process
dictates the polarity of the electrode cable. These con­nections should be checked periodically and tightened
with a wrench.

Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops. Avoid coiling long
cables on the machine when welding.

INSTALLATION

A-6 A-6

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

FIGURE A.1 – RANGER 250 OUTPUT CONNECTIONS

CHOKE

RUN

START HIGH

IDLER

AUTO

G3668 VM

STOP

K NO.- CODE - SERIAL NO.

OUTPUT

20 CV

120 CC

22 CV

155 CC

24 CV

190 CC

17 CV
85 CC

26 CV

220 CC

28 CV

250 CC

14 CV
50 CC

12 CV
20 CC

THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA

CV-WIRE

ARC CONTROL

WELD MODE

PIPE

CC-STICK

TOUCH START TIG

SOFT CRISP

+8

+6

+4

+2

0

-2

-4

-6

-8

-10

+10

WELD

TERMINALS ON

WIRE FEEDER

VOLTMETER

REMOTELY

CONTROLLED

NRTL/C

CIRCUIT

BREAKERS

120/240 V

120 V

WELDER OUTPUT RATING

VOLTS

DUTY CYCLE

250 DC 100% 25

80V MAX OCV AT RATED 3700 RPM

AMPS

AUXILIARY POWER RATING

VOLTS

DUTY CYCLE

WATTS

8,000

100% 120/240

AVAILABLE POWER IS REDUCED WHILE WELDING

SINGLE PHASE 60 HZ

SIMULTANEOUS WELDING AND POWER

WELD CURRENT

AMPS

AUX. POWER

WATTS

240V.RECEPTACLE

AMPS

0
100
150
200
250

8000
5000
3000
1500

0

33
21
13
6
0

NEUTRAL GROUND TO FRAME

Hobbs

QUARTZ

HOURS

0 0 0 0 0 0

1

2

4

3

1. 120 VAC
RECEPTACLES

2. 120/240 VAC
RECEPTACLES

3. WELD OUTPUT
TERMINALS

4. GROUND STUD

WARNING

TABLE A.1 – TOTAL COMBINED LENGTH

OF ELECTRODE AND WORK CABLES

Cable

Cable Size for

Length

250 Amps

100% Duty Cycle

0-100 ft. (0-30 meters) 1 AWG
100-200 ft. (30-46 meters) 1 AWG
150-200 ft. (46-61 meters) 1/0 AWG

CABLE INSTALLATION

Install the welding cables to your Ranger 250 as fol­lows.

1. The engine must be OFF to install welding cables.

2. Remove the flanged nuts from the output terminals.

3. Connect the electrode holder and work cables to
the weld output terminals. The terminals are iden­tified on the case front.

4. Tighten the flanged nuts securely.

5. Be certain that the metal piece you are welding (the
“work”) is properly connected to the work clamp
and cable.

6. Check and tighten the connections periodically.

• Loose connections will cause the output terminals to

overheat. The terminals may eventually melt.

• Do not cross the welding cables at the output termi-

nal connection. Keep the cables isolated and sepa­rate from one another.

AUXILIARY POWER RECEPTACLES

The auxiliary power of the Ranger 250 consists of two
20 amp-120 VAC (5-20R) duplex receptacles and one
50 amp 120/240 VAC (14-50R) receptacle. The 240
VAC receptacle can be split for single-phase 120 VAC
operation.

The auxiliary power capacity is 8,000 watts of 60 Hz,
single-phase power. The auxiliary power capacity rat­ing in watts is equivalent to volt-amperes at unity power
factor. The maximum permissible current of the 240
VAC output is 33 amps. The 240 VAC output can be
split to provide two separate 120 VAC outputs with a
maximum permissible current of 33 amps per output to

two separate 120 VAC branch circuits (these circuits
cannot be paralleled). Output voltage is within ±10% at
all loads up to rated capacity.

The 120 VAC auxiliary power receptacles should only
be used with three-wire grounded type plugs or
approved double insulated tools with two-wire plugs.
The current rating of any plug used with the system
must be at least equal to the current capacity of the
associated receptacle.

NOTE: The 240 VAC receptacle has two 120 VAC cir­cuits, but they are of opposite polarities and cannot be
paralleled.

STANDBY POWER CONNECTIONS

The Ranger 250 is suitable for temporary, standby or
emergency power using the engine manufacturer’s rec­ommended maintenance schedule.

The Ranger 250 can be permanently installed as a
standby power unit for 240 VAC, three-wire, single­phase, 35 amp service. Connections must be made by
a licensed electrician who can determine how the
120/240 VAC power can be adapted to the particular
installation and comply with all applicable electrical
codes. The following information can be used as a
guide by the electrician for most applications. Refer to
the connection diagram in Figure A-2.

1. Install the double-pole, double-throw switch
between the power company meter and the
premises disconnect. Switch rating must be the
same or greater than the customer’s premises dis­connect and service over current protection.

2. Take necessary steps to assure load is limited to
the capacity of the Ranger 250 by installing a 35
amp, 240 VAC double-pole circuit breaker.

Maximum rated load for each leg of the 240 VAC
auxiliary is 33 amperes. Loading above the rated
output will reduce output voltage below the allow­able ±10% of rated voltage, which may damage
appliances or other motor-driven equipment and
may result in overheating of the Ranger 250 engine
and/or alternator windings.

3. Install a 50 amp, 120/240 VAC plug (NEMA Type
14-50) to the double-pole circuit breaker using No.
6, 4-conductor cable of the desired length. (The 50
amp, 120/240 VAC plug is available in the optional
K802R plug kit or as part number T12153-9.)

4. Plug this cable into the 50 amp, 120/240 VAC
receptacle on the Ranger 250 case front.

INSTALLATION

A-7 A-7

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

CAUTION

INSTALLATION

A-8 A-8

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

FIGURE A.2 – CONNECTION OF THE RANGER 250 TO PREMISES WIRING

240 Volt

60 Hz.
3-Wire

Service

POWER

COMPANY

METER

240 VOLT

120 VOLT

120 VOLT

LOAD

N

NEUTRAL
BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

N

NOTE: No. 8 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

240 VOLT

GROUNDED CONDUCTOR

35AMP

240 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLT

RECEPTACLE

• Only a licensed, certified, trained electrician should install the machine to a premises or residential elec­trical system. Be certain that:

• The installation complies with the National Electrical Code and all other applicable electrical codes.

• The premises is isolated and no feedback into the utility system can occur. Certain state and local laws

require the premises to be isolated before the generator is linked to the premises. Check your state and
local requirements.

• A double-pole, double-throw transfer switch in conjunction with the properly rated double-throw circuit
breaker is connected between the generator power and the utility meter.

WARNING

Section B-1 Section B-1

RANGER 250

TABLE OF CONTENTS

- OPERATION SECTION -

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

Operating Instructions.................................................................................................................B-2

Safety Instructions.......................................................................................................................B-2

General Description ....................................................................................................................B-2

Design Features ..........................................................................................................................B-3

Controls and Settings..................................................................................................................B-3

Engine Controls....................................................................................................................B-4

Welding Controls ..................................................................................................................B-5

Engine Operation........................................................................................................................B-5

Before Starting the Engine ...................................................................................................B-5

Starting the Engine...............................................................................................................B-6

Stopping the Engine.............................................................................................................B-6

Welder Operation........................................................................................................................B-7

General Operation................................................................................................................B-7

Stick Welding........................................................................................................................B-8

Constant Current (CC-Stick) Welding .............................................................................B-8

Pipe Welding ...................................................................................................................B-8

TIG Welding.................................................................................................................... ......B-9

Wire Welding-CV..................................................................................................................B-9

Arc Gouging.................................................................................................................... ......B-9

Auxiliary Power ...........................................................................................................................B-9

Simultaneous Welding and Auxiliary Power Loads............................................................B-10

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

OPERATING INSTRUCTIONS

Read and understand this entire section before operat­ing your Ranger 250.

SAFETY INSTRUCTIONS

Do not attempt to use this equipment until you have
thoroughly read all the operating and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating and maintenance instructions and parts lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such
as output terminals or internal wiring.

• Insulate yourself from the work and
ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be dan­gerous.

• Keep your head out of fumes.

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

WELDING SPARKS can cause
fire or explosion.

• Keep flammable material away.

• Do not weld on containers that have held
combustibles.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

ENGINE EXHAUST can kill.

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

• Do not stack anything on or near the
engine.

MOVING PARTS can injure.

• Do not operate this equipment with any
of its doors open or guards off.

• Stop the engine before servicing it.

• Keep away from moving parts.

Only qualified personnel should install, use, or ser­vice this equipment.

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door closed
and the side panels in place. These provide maximum
protection from moving parts and insure proper cooling
air flow.

GENERAL DESCRIPTION

The Ranger 250 is a gasoline-engine-powered DC
multi-process welding power source and 120 / 240
VAC power generator. The engine drives a generator
that supplies three-phase power for the DC welding cir­cuit and single-phase power for the AC auxiliary out­lets. The DC welding control system uses state of the
art Chopper Technology (CT™) for superior welding
performance.

OPERATION

B-2 B-2

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

WARNING

WARNING

DESIGN FEATURES

• Single, full-range output control dial.

• 4 welding modes: CC-stick, downhill stick welding on
pipe, CV wire welding and Touch-Start TIG™ (elimi­nates high frequency and tungsten contamination).

• Output at welding terminals controlled by electronic
contactor. Can be switched to “On”, or to “Remotely
Controlled”. Contactor auto-activated when con­nected. 6-pin connector for remote output.

• Many wire feeder combinations: 14-pin connector for
Lincoln wire feeders LN-25, LN-23P, LN-7, LN-8
operates when using a Lincoln wire feeder with the
appropriate control cable.

• Smart machine! Remote operation and Magnum®
spool gun; 42VAC for LN-742 and Cobramatic® wire
feeders.

• Wire feed voltmeter switch matches polarity of wire
feeder voltmeter to polarity of electrode.

• 12 gallon fuel capacity allows you to run an extend­ed day.

• Easily check fuel level during operation and refu­elling with highly visible fuel gauge located next to
the fuel cap on case top side.

• Longer engine life, reduced noise emissions and
greater fuel economy with the automatic engine idler.

• Conveniently located engine maintenance label
under top engine door.

• Engine hour meter for scheduled maintenance.

• Automatic engine shutdown protection for low oil
pressure.

• Electric start. Reduce abnormal charging thanks to
a backlit battery charger system light indicator.

• Oil drain valve (no tools required).

• 8,000 watts of continuous duty AC generator power.

• Up to 33 amps at 240V from the 120V/240V recep­tacle. Circuit breaker protection.

• Two 120V 20A duplex receptacles. Circuit breaker
protection. Will operate up to a 9” grinder.

CONTROLS AND SETTINGS

The gasoline engine stop/start and idler controls are
located on the case front panel. The welder controls are
also located here. See Figure B.1.

OPERATION

B-3 B-3

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

OPERATION

B-4 B-4

RANGER 250

ENGINE CONTROLS

1. RUN/STOP SWITCH: RUN position energizes the
engine prior to starting. STOP position stops the
engine. The oil pressure interlock switch prevents
battery drain if the switch is left in the RUN position
and the engine is not operating.

2. CHOKE: When pulled out, it closes the choke valve
on the engine carburetor for quick starting.

3. START PUSHBUTTON: Energizes the starter
motor to crank the engine.

4. IDLER SWITCH: Has two positions as follows:
A) In the HIGH position, the engine runs at the high

idle speed controlled by the engine governor.

B) In the AUTO position, the idler operates as fol-

lows:

a. When switched from HIGH to AUTO or after

starting the engine, the engine will operate
at high speed for approximately 12 seconds
and then go to low idle speed.

b. When the electrode touches the work or

power is drawn from the auxiliary power

receptacles (approximately 100 watts mini­mum), the engine accelerates and operates
at high speed.

c. When welding ceases or the AC power load

is turned off, a fixed time delay of approxi­mately 12 seconds starts. If the welding or
AC power load is not restarted before the
end of the time delay, the idler reduces the
engine speed to low idle speed.

d. The engine will automatically return to high

idle speed when the welding load or AC
power load is reapplied.

5. ENGINE ALTERNATOR TROUBLE LIGHT: The
yellow engine alternator light is off when the battery
charging system is functioning normally. If the light
turns on, the alternator or the voltage regulator may
not be operating correctly. The light may also come
on if the battery is not holding a charge. It is normal
for the light to come on while starting the engine.

6. ENGINE HOUR METER: Displays the total time

that the engine has been running. This meter is
useful for scheduling prescribed maintenance.

FIGURE B.1 – CASE FRONT PANEL CONTROLS

1

K NO.- CODE - SERIAL NO.

Hobbs

6

7

QUARTZ

0 0 0 0 0 0

HOURS

THE LINCOLN ELECTRIC COMPANY CLEVELAND, OHIO USA

WELD MODE

CV-WIRE

PIPE

CC-STICK

TOUCH START TIG

8

RUN

STOP

OUTPUT

20 CV

120 CC

17 CV
85 CC

14 CV
50 CC

12 CV
20 CC

ARC CONTROL

SOFT CRISP

-2

-4

-6

-8

-10

START HIGH

CHOKE

22 CV

155 CC

24 CV

190 CC

220 CC

28 CV

250 CC

0

+2

+4

+6

+8

+10

26 CV

TERMINALS ON

CONTROLLED

NEUTRAL GROUND TO FRAME

WELD

REMOTELY

9

CIRCUIT

BREAKERS

120 V

SIMULTANEOUS WELDING AND POWER

WELD CURRENT

AMPS

0
100
150
200
250

WELDER OUTPUT RATING

DUTY CYCLE

AMPS

250 DC 100% 25

80V MAX OCV AT RATED 3700 RPM

AUX. POWER

VOLTS

120/240 V

240V.RECEPTACLE

AMPS

WATTS

33

8000

21

5000

13

3000

6

1500

0

0

AUXILIARY POWER RATING

DUTY CYCLE

WATTS

100% 120/240

8,000

AVAILABLE POWER IS REDUCED WHILE WELDING

SINGLE PHASE 60 HZ

VOLTS

IDLER

WIRE FEEDER

VOLTMETER

G3668 VM

AUTO

4

3

NRTL/C

2

5

13

12

11

10

OPERATION

B-5 B-5

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

WELDING CONTROLS

7. OUTPUT CONTROL: The OUTPUT dial provides
continuous control of the welding current or weld­ing voltage depending on the selected welding
mode. This control is not active in the CC-STICK,
PIPE, and CV-WIRE modes when a remote con­trol or wire feeder with remote control is connect­ed to either the 6-pin or 14-pin Amphenol.

8. WELD MODE SELECTOR SWITCH: This switch
provides four selectable welding modes:

• CV-WIRE

• PIPE

• CC-STICK

• TOUCH START TIG

9. ARC CONTROL: The ARC CONTROL WIRE/
STICK dial is active in the CV-WIRE and CC­STICK modes, and has different functions in
these modes. This control is not active in the TIG
and PIPE modes.

CC-STICK mode: In this mode, the ARC CON­TROL sets the short circuit current during stick
welding (arc-force). Increasing the number from

-10 to +10 increases the short circuit current and
prevents sticking of the electrode to the plate
while welding. This can also increase spatter. It
is recommended that the ARC CONTROL be set
to the minimum number without electrode stick­ing. Start with a setting at 0.

CV-WIRE mode: In this mode, turning the ARC
CONTROL clockwise from -10 (soft) to +10 (crisp)
changes the arc from soft and washed-in to crisp
and narrow. It acts as an inductance control. The
proper setting depends on the procedure and
operator preference. Start with a setting at 0.

10. 14-PIN AMPHENOL: For attaching wire feeder
control cables to the Ranger 250. Includes con­tactor closure circuit, auto-sensing remote control
circuit, and 120V and 42V power. The remote
control circuit operates the same as the 6-pin
Amphenol. See below.

11. 6-PIN AMPHENOL: For attaching optional
remote control equipment. When in the CC­STICK, PIPE, and CV-WIRE modes and when a
remote control is connected to the Amphenol, the
auto-sensing circuit in the Ranger 250 automati­cally switches the OUTPUT control from control at
the welder to remote control.

When using the TOUCH START TIG mode, the
OUTPUT control on the front of the Ranger 250
sets the maximum current range.

12. WELD TERMINALS CONTROL SWITCH: In the
WELD TERMINALS ON position, the weld output
is electrically hot all the time. In the REMOTELY
CONTROLLED position, the weld output is con­trolled by a wire feeder or amptrol device, and is
electrically off until a remote switch is depressed.

13. WIRE FEEDER VOLTMETER SWITCH: Matches
the polarity of the wire feeder voltmeter to the
polarity of the electrode.

ENGINE OPERATION

DO NOT RUN THE ENGINE AT EXCESSIVE
SPEEDS. The maximum allowable high idle speed for
the Ranger 250 is 3750 RPM, no load. Do NOT adjust
the governor screw on the engine. Severe personal
injury and damage to the machine can result if it is
operated at speeds above the maximum rated speed.

Read and understand all safety instructions included in
the engine operator’s manual that is shipped with your
Ranger 250.

BEFORE STARTING THE ENGINE

Check and fill the engine oil level:

1. Be sure the machine is on a level surface.

2. Open top engine door and remove the engine oil

dipstick and wipe it with a clean cloth. Reinsert the
dipstick and check the level on the dipstick.

3. Add oil (if necessary) to bring the level up to the full

mark. Do not overfill. Close engine door.

4. See the Maintenance section for specific oil rec-

ommendations.

Check and fill the engine fuel tank:

GASOLINE can cause fire or
explosion.

• Stop engine when fueling.

• Do not smoke when fueling.

• Do not overfill tank.

• Avoid contact with skin or breathing of vapor.

• Keep sparks and flame away from tank.

WARNING

WARNING

1. Remove the fuel tank cap.

2. Fill the tank approximately 4 inches (100mm) from
the top of the filler neck to allow for fuel expansion.
(Observe the fuel gauge while filling.) DO NOT
FILL THE TANK TO THE POINT OF OVERFLOW.

3. Replace the fuel cap and tighten securely.

4. See the Maintenance section for specific fuel rec­ommendations.

STARTING THE ENGINE

1. Remove all plugs connected to the AC power
receptacles.

2. Set the IDLER switch to AUTO.

3. Set the RUN/STOP switch to RUN.

4. Pull the choke to the full out position.

5. Press and hold the engine START button until the
engine starts.

6. Release the engine START button when the
engine starts.

7. Push the choke back in.

8. The engine will run at high idle speed for approx­imately 12 seconds and then go to low idle speed.
Allow the engine to warm up at low idle for sever­al minutes before applying a load and/or switch­ing to high idle. Allow a longer warm up time in
cold weather.

Operating the starter motor for more than 5 seconds
can damage the motor. If the engine fails to start,
release the START button and wait 10 seconds before
activating the starter again. Do NOT push the START
button while the engine is running because this can
damage the ring gear and/or the starter motor.

NOTE: Starting a Ranger 250 for the first time, or after
an extended period of time of not operating, will take
longer than normal. The fuel pump has to fill the fuel
line and carburetor. If the engine will not start, see the
Troubleshooting section of this manual.

STOPPING THE ENGINE

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

2. Stop the engine by placing the RUN-STOP switch in
the STOP position.

NOTE: A fuel shut off valve is not required on the
Ranger 250 because the fuel tank is mounted below
the engine.

BREAK-IN PERIOD

Any engine will use a small amount of oil during its
“break-in” period. For the gasoline engine on the
Ranger 250, break-in is about 50 running hours.

Check the oil at least twice a day during break-in.
Change the oil after the first 25 hours of operation.
Change the oil filter at the second oil change. For more
details, see the Maintenance section of this manual.

During break-in, subject the Ranger 250 to moderate
loads. Avoid long periods running at idle. Before stop­ping the engine, remove all loads and allow the engine
to cool several minutes.

OPERATION

B-6 B-6

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

/

CAUTION

CAUTION

WELDER OPERATION

GENERAL INFORMATION

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

• Do not breathe welding fumes or gases.

• Use ventilation or exhaust to remove weld­ing from the breathing area.

• Keep flammable material away.

• Wear eye, ear, and body protection.

The Ranger 250 can deliver from 40 to 250 amps of
constant current for DC stick welding or from 20 to 250
amps of constant voltage current for DC semiautomat­ic wire feed welding. DC TIG welding is possible
across the entire range from 20 to maximum rated out­put. Output can be adjusted by setting the OUTPUT
control dial and the ARC control dial on the output con­trol panel to the settings that are best for your selected
welding process.

NOTE: An unstable or unsatisfactory welding arc can
result if welding cables are too long or are coiled on the
machine when welding. See Table A.1 in the

Installation section. Straighten out coiled cables
before welding.

OPERATION

B-7 B-7

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

WARNING

Onan P216 Kohler CH20 Running Time for

16 hp @ 3600 rpm 12 gallons-hours 12 gallons-hours

gal./hr (liters/hr) gal./hr (liters/hr) Onan/Kohler

Low Idle - No Load
2400 R.P.M. 0.6 (2.3) 0.6 (2.3) 20/20

High Idle - No Load
3700 R.P.M. 0.8 (3.0) 0.8 (3.0) 15/15

DC Weld Output
250 Amps @ 25 Volts 1.7 (6.4) 1.4 (5.3) 7.0/8.6

Auxiliary Power
8,000 Watts 1.8 (6.8) 1.4 (5.3) 6.4/8.6

TABLE B.1 – TYPICAL RANGER 250 FUEL CONSUMPTION

STICK WELDING

The Ranger 250 can be used with a broad range of DC
stick electrodes.

The MODE switch provides two stick welding settings
as follows:

CONSTANT CURRENT (CC-STICK) WELDING

The CC-STICK position of the MODE switch is
designed for horizontal and vertical-up welding with all
types of electrodes, especially low hydrogen. The
OUTPUT control adjusts the full output range for stick
welding.

The ARC control sets the short circuit current during
stick welding (arc-force). Increasing the number from

-10 to +10 increases the short circuit current and pre­vents sticking of the electrode to the plate while weld­ing. This can also increase spatter. It is recommended
that the ARC control be set to the minimum number
without electrode sticking. Start with the dial set at 0.

PIPE WELDING

This slope-controlled setting is intended for “out-of­position” and “downhill” pipe welding where the opera­tor would like to control the current level by changing
the arc length. The OUTPUTcontrol dial adjusts the full
output range for pipe welding. The ARC control is not
active in the PIPE mode.

OPERATION

B-8 B-8

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

Tungsten
Electrode
Diameter

in. (mm)

2-15
5-20

15-80

70-150

150-250
250-400

400-500
500-750

750-1000

3
3
3

10-20
15-30

25-40
40-55

55-80

180-125

3-8 (2-4)
5-10 (3-5)
5-10 (3-5)

5-10 (3-5)
13-17 (6-8)

15-23 (7-11)
21-25 (10-12)

23-27 (11-13)
28-32 (13-15)

3-8 (2-4)
5-10 (3-5)
5-10 (3-5)

9-13 (4-6)
11-15 (5-7)

11-15 (5-7)
13-17 (6-8)

18-22 (8-10)
23-27 (11-13)

TIG TORCH

Nozzle
Size

4, 5

Approximate Argon Gas Flow Rate

C.F.H. (l/min.)

DCEN (-) DCEP (+)

#4, #5, #6

#5, #6
#6, #7, #8

#8, #10

0 .010 (.25)

0.020 (.50)

0.040 (1.0)
1/16 (1.6)
3/32 (2.4)

1/8 (3.2)
5/32 (4.0)

3/16 (4.8)
1/4 (6.4)

1%, 2%
Thoriated
Tungsten

1%, 2%

Thoriated

Tungsten

Aluminum Stainless Steel

TABLE B.2 – TYPICAL CURRENT RANGES1FOR TUNGSTEN ELECTRODES

2

1

When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shield­ing gases.

2

Tungsten electrodes are classified as follows by the American Welding Society (AWS):

Pure EWP
1% Thoriated EWTh-1

2% Thoriated EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated
Tungsten in AC and DC applications.

3

DCEP is not commonly used in these sizes.

4

TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:

# 4 = 1/4 in. (6 mm)
# 5 = 5/16 in. (8 mm)
# 6 = 3/8 in. (10 mm)
# 7 = 7/16 in. (11 mm)
# 8 = 1/2 in. (12.5 mm)
#10 = 5/8 in. (16 mm)

5

TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are
less prone to breakage, but cannot withstand high temperatures and high duty cycles.

TIG WELDING

The TOUCH START TIG setting of the MODE switch is
for DC TIG (Tungsten Inert Gas) welding. To initiate a
weld, the OUTPUT control is first set to the desired cur­rent and the tungsten is touched to the work. During
the time the tungsten is touching the work there is very
little voltage or current and, in general, no tungsten
contamination. Then the tungsten is gently lifted off the
work in a rocking motion, which establishes the arc.

The ARC CONTROL is not active in the TIG mode.
The Ranger 250 can be used in a wide variety of DC

TIG welding applications. In general the “Touch Start”
feature allows contamination-free starting without the
use of a Hi-frequency unit. If desired, the K930-2 TIG
Module can be used with the Ranger 250. The follow­ing settings are for reference.

Ranger 250 settings when using the K930-2 TIG
Module with an Amptrol or Arc Start Switch:

a. Set the MODE Switch to the TOUCH START TIG

setting.
b. Set the “IDLER” Switch to the “AUTO” position.
c. Set the "WELD TERMINALS” switch to the

“REMOTELY CONTROLLED” position. This will

keep the solid state contactor open and provide a

“cold” electrode until the Amptrol or Arc Start switch

is pressed.
When using the TIG Module, the OUTPUT control on

the Ranger 250 is used to set the maximum range of
the CURRENT.

WIRE WELDING-CV

Connect a wire feeder to the Ranger 250 according to
the instructions in the Accessories section.

In the CV-WIRE mode, the Ranger 250 can be used
with a broad range of flux cored wire (Innershield and
Outershield) electrodes and solid wires for MIG weld­ing (gas metal arc welding). Welding can be finely
tuned using the ARC CONTROL. Turning the ARC
CONTROL clockwise from -10 (soft) to +10 (crisp)
changes the arc from soft and washed-in to crisp and
narrow. It acts as an inductance control. The proper
setting depends on the procedure and operator prefer­ence. Start with the dial set at 0.

Some recommended Innershield electrodes are:
NR-311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H.
Recommended Outershield electrodes are: 0S-70,
0S-71M.

Some recommended solid wires for MIG welding are:
.035 (0.9 mm), and .045 (1.1 mm), L-50 and L-56, .035
(0.9 mm) and .045 (1.1 mm) Blue Max MIG 308 LS.

For any electrodes, including those above, the proce­dures should be kept within the rating of the machine.

ARC GOUGING

The Ranger 250 can be used for limited arc gouging.
For optimal performance, set the MODE switch to CC­STICK and the ARC CONTROL to +10.

Set the OUTPUT CONTROL to adjust output current to
the desired level for the gouging electrode being used
according to the ratings in Table B.3.

TABLE B.3 – CURRENT RANGE

PER ELECTRODE DIAMETER

Electrode Current Range

Diameter (DC, Electrode Positive)

1/8" 30-60 Amps
5/32" 90-150 Amps
3/16" 150-200 Amps

AUXILIARY POWER

Be sure that any electrical equipment plugged into the
generator AC power receptacles can withstand a ±10%
voltage and a ±3% frequency variation.

Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
regardless of the welding control settings as long as no
welding current is being drawn.

The auxiliary power of the Ranger 250 consists of two
20 amp-120 VAC (5-20R) duplex receptacles and one
50 amp 120/240 VAC (14-50R) receptacle. The 240
VAC receptacle can be split for single-phase 120 VAC
operation.

The auxiliary power capacity is 8,000 watts of 60 Hz,
single-phase power. The auxiliary power capacity rat­ing in watts is equivalent to volt-amperes at unity power
factor. The maximum permissible current of the 240
VAC output is 33 amps.

OPERATION

B-9 B-9

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

WARNING

The 240 VAC output can be split to provide two sepa­rate 120 V AC outputs with a maximum permissible cur­rent of 33 amps per output to two separate 20 amp
branch circuits. (These circuits cannot be paralleled.)
Output voltage is within ±10% at all loads up to rated
capacity.

The 120 VAC auxiliary power receptacles should only
be used with three-wire, grounded type plugs or
approved double-insulated tools with two-wire plugs.
The current rating of any plug used with the system
must be at least equal to the current capacity of the
associated receptacle. For extension cord lengths, see
Table B.5.

NOTE: The 240 VAC receptacle has two circuits, each
of which measures 120 VAC to neutral. However, they
are of opposite polarity and cannot be paralleled.

SIMULTANEOUS WELDING AND
AUXILIARY POWER LOADS

The auxiliary power ratings are with no welding load.
Simultaneous welding and power loads are specified in
Table B.4. The permissible currents shown assume
that current is being drawn from either the 120 VAC or
240 VAC supply (not both at the same time).

OPERATION

B-10 B-10

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

* Each duplex receptacle is limited to 20 amps.
** Not to exceed 25 amps per 120 VAC branch circuit when splitting the 240 VAC output.

TABLE B.4 – RANGER 250 SIMULTANEOUS WELDING AND POWER LOADS

Welding Permissible Power-Watts

Permissible Auxiliary

Output- Amps (Unity Power Factor)

Current in Amps

@ 120 VAC* @ 240 VAC**

0 8000 40* 33
100 5000 40* 21
150 3000 25 12.5
200 1500 12.5 6.3
250 0 0 0

TABLE B.5 – RANGER 250 EXTENSION CORD LENGTH RECOMMENDATIONS

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

Current Voltage

Load

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

(Amps) (Volts)

(Watts)

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
15 120 1800 30 (9) 40 (12) 75 (23) 125 (38) 175 (53) 300 (91)
20 120 2400 30 (9) 50 (15) 88 (27) 138 (42) 225 (69)
15 240 3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)
20 240 4800 60 (18) 100 (30) 175 (53) 275 (84) 450 (137)
33 240 8000 60 (18) 100 (30) 175 (53) 250 (76)

Conductor size is based on maximum 2.0% voltage drop.

TABLE OF CONTENTS

- ACCESSORIES -

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

Options/Accessories ...................................................................................................................C-2

Field Installed Options ....................................................................................................... ..C-2

TIG Welding Accessories .....................................................................................................C-2

Semiautomatic FCAW and MIG Welding Accessories.........................................................C-2

Connection of Lincoln Electric Wire Feeders.......................................................................C-3

Connection of the K867 Universal Adapter ....................................................................C-3

Connection of the LN-25 “Across the Arc”.....................................................................C-4

Connection of the LN-25 with 42V Remote Output Control Module..............................C-5

Connection of the LN-25 with K857 Remote Control .....................................................C-6

Connection of the LN-7 Using the K584 Control Cable.................................................C-7

Connection of the LN-8 Using the K595 Control Cable.................................................C-8

Connection of the LN-742..............................................................................................C-9

Section C-1 Section C-1

RANGER 250

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

OPTIONS/ACCESSORIES

FIELD INSTALLED OPTIONS

The following options/accessories are available for
your Ranger 250 from your local Lincoln distributor.

K957-1 HEAVY DUTY, TWO-WHEEL TRAILER FOR
SMALL WELDERS - For road, off-road and in-plant

and yard towing. (For highway use, consult applicable
federal, state and local laws regarding requirements for
brakes, lights, fenders, etc.)

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

K1770-1 UNDERCARRIAGE (FACTORY) - For mov-

ing by hand on a smooth surface. One or two gas
cylinders can be mounted on the rear of the undercar­riage with the installation of K1745-1 Cylinder
Holder(s).

K1739-1 CABLE CARRIER KIT - For use on K1737-1
and K1770-1 Undercarriages.

K1745-1 SINGLE GAS CYLINDER HOLDER - For use
on K1770-1 Undercarriage. One or two may be
installed on an undercarriage.

K1788-1 ROLL CAGE - Gives added damage protec­tion.

K886-2 CANVAS COVER - Protects machine when
not in use.

S24647 SPARK ARRESTER - Mounts inside exhaust
pipe.

K702 ACCESSORY KIT - Accessory set includes 35 ft.
(10.7 meters) 2 AWG electrode cable, 30 ft. (9.1
meters) 2 AWG work cable, headshield with No. 12 fil­ter, GC300 work clamp and Cooltong 300 electrode
holder. Cables are rated at 250 amps, 40% duty cycle.

K857 28 ft. (8.5m) or K857-1 100 ft. (30.4m)
REMOTE CONTROL - Portable control provides same

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

K1690-1 GFCI RECEPTACLE KIT - Includes one UL
approved 120 volt ground fault circuit interrupter duplex
type receptacle with cover and installation instructions.
Replaces the factory installed 120V duplex receptacle.
Each receptacle of the GFCI Duplex is rated at 20
amps. The maximum total current from the GFCI
Duplex is limited to 20 amps. Two kits are required.

K802-N POWER PLUG KIT - Provides four 120 volt
plugs rated at 20 amps each and one dual voltage, full
KVA plug rated at 120/240 volts, 50 amps.

K802-R POWER PLUG KIT - Provides four 120 volt

plugs rated at 15 amps each and one dual voltage, full
KVA plug rated at 120/240 volts, 50 amps.

T12153-9 50 AMP, 120/240V POWER PLUG -

Provides one dual voltage plug for full KVA power.

TIG WELDING ACCESSORIES

K1783-9 TIG TORCH - For TIG welding with shielding

gas. Includes 25 feet of cable.

K963-2 - Hand Amptrol.
K870 - Foot Amptrol.
NOTE: TIG welding requires a Magnum™ TIG Gun,

appropriate Magnum Parts Kit and argon gas.

SEMIAUTOMATIC FCAW AND MIG
WELDING ACCESSORIES

LN-25 WIRE FEEDER K449 - This portable unit pro-

vides CC/CV for flux-cored arc welding (FCAW) and
metal inert gas welding (MIG). Includes a gas solenoid
and an internal contactor that allows across-the-arc
operation with no control cable. The LN-25 provides a
“cold” electrode until the gun trigger is pressed. For
voltage control at the feeder, a K444-1 Remote Voltage
Control Kit or K857 Remote Control is required. Refer
to connection instructions later in this section.

LN-7 OR LN-8 WIRE FEEDER - Semiautomatic, con­stant speed wire feeders.

NOTE: Gas-shielded welding requires a Magnum Gun.
Gasless welding requires an Innershield Gun.

LN-742 WIRE FEEDER - A semiautomatic wire feeder
with “cold” electrode. Refer to connection instructions
later in this section.

MAGNUM SPOOL GUN (K487-25) - A lightweight,
semiautomatic wire feeder for aluminum welding with
argon gas. Has built-in remote wire speed control in
the handle. Requires the K488 SG Control Module.
Refer to connection instructions later in this section.

SG CONTROL MODULE (K488) - Controls wire speed
and gas flow. Provides the required control interface
between the Ranger 250 and the K487-25 Magnum
Spool Gun. Requires the K691-10 Input Cable.

K444-1 REMOTE VOLTAGE CONTROL - Provides
voltage adjustment control at the feeder. Includes 25
feet of cable.

K126-2 INNERSHIELD GUN - For gasless welding.
Includes 15 feet of cable.

K470-2 MAGNUM GUN CONNECTOR KIT - For gas­shielded welding.

K466-1 MAGNUM GUN CONNECTOR KIT - For con­necting the Magnum 300 MIG Gun to the feeder for
gas-shielded welding.

ACCESSORIES

C-2 C-2

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

CONNECTION OF LINCOLN
ELECTRIC WIRE FEEDERS

ELECTRIC SHOCK can kill.

• Do not operate with panels open.

• Disconnect NEGATIVE (-) BATTERY
LEAD before servicing.

• Do not touch electrically live parts.

MOVING PARTS can injure.

• Keep guards in place.

• Keep away from moving parts.

• Only qualified personnel should install,
use or service this equipment.

CONNECTION OF THE RANGER 250 TO
WIRE FEEDERS USING K867 UNIVERSAL
ADAPTER (SEE FIGURE C.1)

NOTE: When you use the Ranger 250 with non-Lincoln

Electric wire feeders or with certain earlier models of
Lincoln wire feeders, you will require the K867
Universal Adapter. The following discussion and con­nection diagram explain in general how to make the
proper connections.

1. Shut the welder off.

2. Connect the electrode cable from the wire feeder to
the “+” terminal of the welder. Connect the work
cable to the “-” terminal of the welder.

NOTE: Welding cable must be sized for current and
duty cycle of application.

3. Connect the K867 Universal Adapter to the 14-pin
amphenol of the Ranger 250 as shown in Figure
C.1. Make the proper connections for local or
remote control according to Figure C.1 and the fol­lowing NOTES, indicated on the figure:

A. These leads are not used for the Ranger 250.

Insulate each unused lead individually.

B. For wire feeders that return a signal for welding

output, use an isolation relay to close leads 2
and 4.

C. Refer to the Operation section of this manual

for maximum wire feeder auxiliary current draw.

4. Set the “MODE” switch to the “CV-WIRE” position.

5. Place the “IDLER” switch in the “AUTO” position.

Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control cir­cuits may be damaged. The engine governor setting is
preset at the factory – do not adjust above RPM spec­ifications listed in this manual.

6. Set the “VOLTMETER” switch to “+” or “-” depend­ing on the polarity chosen.

7. Set the ARC control to “0” initially and adjust to suit.

8. Adjust wire feed speed at the wire feeder.

ACCESSORIES

C-3 C-3

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

WARNING

FIGURE C.1 – RANGER 250/K867 UNIVERSAL ADAPTER CONNECTION DIAGRAM

ELECTRODE CABLE
TO WIRE FEED UNIT

TO WORK

14-PIN
AMPHENOL

A

B

C

K867 UNIVERSAL
ADAPTER PLUG

+–

CAUTION

CONNECTION OF THE LN-25 TO THE
RANGER 250 “ACROSS THE ARC”
(SEE FIGURE C.2.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-25 to the
“-” terminal of the welder. Connect the work cable
to the “+” terminal of the welder.

NOTE: Figure C.2 shows the electrode connected for
negative polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
Ranger 250 output terminals.

NOTE: Welding cable must be sized for current and
duty cycle of application.

3. Set the “VOLTMETER” switch to “+” or “-” depend­ing on the polarity chosen.

4. Set the “MODE” switch to the “CV-WIRE” position.

5. Attach the single lead from the LN-25 control box
to the work using the spring clip on the end of the
lead. This is only a control lead – it carries no
welding current.

6. Place the “IDLER” switch in the “AUTO” or “HIGH”
position as desired.

If you are using an LN-25 without an internal contactor,
the electrode will be “HOT” when the Ranger 250 is
started.

7. Place the “WELD TERMINALS” switch in the
“WELD TERMINALS ON” position.

8. Adjust wire feed speed at the LN-25 and adjust the
welding voltage with the output “CONTROL” at the
LN-25 if optional remote control kit is used.

9. Set the ARC control to “0” initially and adjust to suit.

ACCESSORIES

C-4 C-4

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

CAUTION

FIGURE C.2 – RANGER 250/LN-25 ACROSS THE ARC CONNECTION DIAGRAM

-

-

+ –

ACCESSORIES

C-5 C-5

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

CONNECTION OF THE LN-25 TO THE
RANGER 250 WITH 42 VOLT REMOTE
OUTPUT CONTROL MODULE
(SEE FIGURE C.3.)

1. Shut the welder off.

2. Connect the electrode cable from the K626-XX
Input Cable Assembly to the “-” terminal of the
welder and to the LN-25 Wire Feeder. Connect the
work cable to the “+” terminal of the welder.

NOTE: Figure C.3 shows the electrode connected for
negative polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
Ranger 250 output terminals.

NOTE: Welding cable must be sized for current and
duty cycle of application.

3. Connect the input cable from the K626-XX Input
Cable Assembly to the 14-pin amphenol on the
Ranger 250 and the input cable plug on the LN-25.

4. Set the “VOLTMETER” switch to “+” or “-” depend­ing on the polarity chosen.

5. Set the “MODE” switch to the “CV-WIRE” position.

6. Place the “IDLER” switch to the “AUTO” or “HIGH”
position as desired.

Any increase of the high idle engine RPM by changing
the governor setting or overriding the throttle linkage
will cause an increase in the AC auxiliary voltage. If
this voltage goes over 140 volts, wire feeder control cir­cuits may be damaged. The engine governor setting is
preset at the factory – do not adjust above RPM spec­ifications listed in this manual.

7. Place the “WELD TERMINALS” switch in the
“REMOTELY CONTROLLED” position.

8. Adjust wire feed speed and voltage at the LN-25.

9. Set the ARC control to “0” initially and adjust to suit.

FIGURE C.3 – RANGER 250/LN-25 WITH

42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM

CAUTION

-

+–

CONNECTION OF THE LN-25 TO THE
RANGER 250 “ACROSS THE ARC”
WITH K857 REMOTE CONTROL
(SEE FIGURE C.4.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-25 to the
“-” terminal of the welder. Connect the work cable
to the “+” terminal of the welder.

NOTE: Welding cable must be sized for current and
duty cycle of application.

NOTE: Figure C.4 shows the electrode connected for
negative polarity. To change polarity, shut the welder
off and reverse the electrode and work cables at the
Ranger 250 output terminals.

3. Connect the K857 Remote Control to the 6-pin
amphenol on the Ranger 250.

4. Attach the single lead from the LN-25 to the work
using the spring clip on the end of the lead. This is
only a sense lead – it carries no welding current.

5. Place the “IDLER” switch in the “AUTO” or “HIGH”
position, as desired.

If you are using an LN-25 without an internal contactor,
the electrode will be “HOT” when the Ranger 250 is
started.

6. Set the “MODE” switch to “CV-WIRE.”

7. Set the “WELD TERMINALS” switch to “WELD
TERMINALS ON.”

8. Set the “VOLTMETER” switch to “+” or “-”
depending on the polarity chosen.

9. Adjust wire feed speed at the LN-25 and adjust
the welding voltage with the K857 if optional
remote control is used.

10. Adjust the “ARC” control to “0” initially and adjust
to suit.

ACCESSORIES

C-6 C-6

RANGER 250

Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

FIGURE C.4 – RANGER 250/LN-25 ACROSS THE ARC

CONNECTION DIAGRAM WITH K857 REMOTE CONTROL

(RANGER 300 DLX
ONLY)

6 PIN

AMPHENOL

TO WORK

14 PIN
AMPHENOL

LN-25

ELECTRODE CABLE

WIRE FEEDER

TO WORK

WORK CLIP LEAD

OPTIONAL K857

REMOTE CONTROL

ELECTRODE

TO WORK

-

-

CAUTION

+

–