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Lincoln Electric IM919 - page 1
Ranger 250 OPERA TOR’S MANUAL IM919 March, 2008 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AN ...
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Lincoln Electric IM919 - page 2
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. ________________________________________________ ...
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Lincoln Electric IM919 - page 3
ii SAFETY ii ARC RA YS 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 ski ...
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Lincoln Electric IM919 - page 4
FOR ELECTRICALL Y 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 manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical ...
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Lincoln Electric IM919 - page 5
iv SAFETY iv Mar. ʻ93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les c ...
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Lincoln Electric IM919 - page 6
v v 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay ...
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Lincoln Electric IM919 - page 7
vi vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications ....................................................................................................... A-1 Machine Specifications ..................... ...
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Lincoln Electric IM919 - page 8
vii vii T ABLE OF CONTENTS Maintenance ......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................ ...
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Lincoln Electric IM919 - page 9
Make/Model Description Horsepower Operating Displacement cu. in.(cu. cm) Starting Capacities @ 3600 RPM SPEED Bore x Stroke in.(mm) System RANGER® 250 1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up t o rated capacity. When welding, available auxiliary power will be red ...
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Lincoln Electric IM919 - page 10
A-2 INST ALLA TION RANGER® 250 A-2 MACHINE SPECIFICA TIONS - Ranger® 250 ( K1725-10, K1725-1 1, K1725-12) RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS (2) 120VAC Duplex (5-20R) Two 20AMP for Two Duplex Receptacle 20AMP for Battery Charging Circuit (1) 120/240VAC Dual Voltage One 50AMP for Dual Voltage (2-Pole) 15AMP for 42V ...
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Lincoln Electric IM919 - page 11
A-3 INST ALLA TION RANGER® 250 A-3 LIFTING The RANGER® 250 weighs approximately 575 lbs. with a full tank of gasoline. A lift bail is mounted to the machine and should always be used when lifting the machine. ADDITIONAL SAFETY PRECAUTIONS • Lift only with equipment of adequate lifting capacity. • Be sure machine is stable when lifting. • Do ...
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Lincoln Electric IM919 - page 12
A-4 INST ALLA TION A-4 TOWING The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle (1) is Lincolnʼs K957-1. If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the f ...
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Lincoln Electric IM919 - page 13
T he RANGER® 250 is shipped with the negative battery cable disconnected. Make certain that the RUN-STOP switch is in the STOP position. Remove the two screws from the rear battery tray using a screwdriver or a 3/8" socket. Attach the negative battery cable to the negative battery terminal and tighten using a 1/2" socket or wrench. NOTE: ...
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Lincoln Electric IM919 - page 14
WELDING TERMINALS The Ranger® 250 is equipped with a toggle switch for select- ing "hot" welding terminal when in the "WELD TERMINALS ON" position or "cold" welding terminal when in the "REMOTE- LY CONTROLLED" position. WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the ou ...
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Lincoln Electric IM919 - page 15
A-7 INST ALLA TION RANGER® 250 A-7 240 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. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS. 240 VOLT GROUNDED CONDUCTOR 50AMP 240 VOLT D ...
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Lincoln Electric IM919 - page 16
A-8 INST ALLA TION RANGER® 250 A-8 CONNECTION OF LINCOLN ELEC- TRIC WIRE FEEDERS Connection of LN-7 or LN-8 to the Ranger® 250 1. Shut the welder off. 2. Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in Section F 3. Set the "WIRE FEEDER VOLTMETER" switch to either "+" or "-" as requi ...
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Lincoln Electric IM919 - page 17
A-9 INST ALLA TION A-9 7 . Set the "IDLE" switch to the "AUTO" position. When not welding, the Ranger® 250 engine will be at the low idle speed. If you are using an LN-25 with an internal contactor, the electrode is not energized until the gun trigger is closed. 8. When the gun trigger is closed, the current sens- ing circuit w ...
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Lincoln Electric IM919 - page 18
B-1 OPERA TION RANGER® 250 B-1 GENERAL DESCRIPTION The Ranger® 250 is a gasoline engine powered DC multi-process welding power source and 120 / 240 volt AC power generator. The engine drives a genera- tor that supplies three phase power for the DC weld- ing circuit and single phase power for the AC auxiliary outlets. The DC welding control system ...
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Lincoln Electric IM919 - page 19
B-2 OPERA TION B-2 WELDING CONTROLS: 1. OUTPUT CONTROL: The CONTROL dial provides continuous control of the welding current or welding voltage depending on the selected welding mode. This control is not active in the CC-STICK, DOWN HILL PIPE, and CV-WIRE modes when a remote control or wire feeder with remote control is connected to either the 6 pin ...
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Lincoln Electric IM919 - page 20
B-3 OPERA TION B-3 4. WELD OUTPUT TERMINALS WITH FLANGE NUT : Provides a connection point for the electrode and work cables. Output stud covers provided on code 11270 and above. 5. GROUND STUD: (graphic) Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. 6. 14-PIN CONNECTOR: For attaching ...
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Lincoln Electric IM919 - page 21
B-4 OPERA TION B-4 Operating the starter motor for more than 5 seconds can damage the motor. If the engine fails to start, release the switch and wait 10 seconds before opera- tion the starter again. Do NOT push the START button while the engine is running because this can damage the ring gear and/or the starter motor. ----------------------------- ...
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Lincoln Electric IM919 - page 22
B-5 OPERA TION B-5 TIG WELDING The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the CONTROL dial is first set to the desired current and the tung- sten is touched to the work. During the time the tungsten is touching the work there is very little voltage or current and, in general, no tu ...
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Lincoln Electric IM919 - page 23
B-6 OPERA TION B-6 ARC GOUGING The Ranger® 250 can be used for limited arc gouging. For optimal performance, set the MODE switch to CC- STICK and the ARC CONTROL to +10. Set the CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table. Carbon Diameter Current Ra ...
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Lincoln Electric IM919 - page 24
C-1 ACCESSORIES C-1 RECOMMENDED OPTIONAL EQUIPMENT K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.). Order: K957-1 Trailer K958-1 Ball Hitch K958-2 Lunette Eye Hitch K9 ...
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Lincoln Electric IM919 - page 25
SUBARU ROBIN EH65 ENGINE Code Number 11422 and above Subaru Robin 248-65801-00, Fram PH4967 Subaru Robin 263-32610-A1 N/A Subaru Robin 011-00600-20 Subaru Robin X65-01407-30, NGK BPR4EY BCI Group 58 (435 CCA) D-1 MAINTENANCE D-1 RANGER® 250 KOHLER ENGINE (1) Service more frequently when used in dusty areas and/or at high ambient temperatures. SAFE ...
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Lincoln Electric IM919 - page 26
D-2 MAINTENANCE D-2 ENGINE OIL CHANGE Drain the oil while the engine is warm to assure rapid and complete draining. • Remove the oil filler cap and dipstick. Remove the yel- low cap from the oil drain valve and attach the flexible drain tube supplied with the machine. Push in and twist the drain valve counterclockwise. Pull the valve out and drai ...
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Lincoln Electric IM919 - page 27
D-3 MAINTENANCE D-3 AIR FIL TER P APER ELEMENT 1. Loosen the cover retaining knob and remove the cover. 2. Remove the pre-cleaner from the paper element. 3. Remove the element cover nut, element cover, and paper element. 4. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged eleme ...
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Lincoln Electric IM919 - page 28
D-4 MAINTENANCE D-4 FUEL FIL TER 1. Check the fuel filter for water accumulation or sedi- ment. 2. Replace the fuel filter if it is found with excessive water accumulation or sediment. ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop. BA TTER Y MAINTENANCE To access the ...
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Lincoln Electric IM919 - page 29
D-5 MAINTENANCE D-5 RANGER® 250 WELDER / GENERA TOR MAINTENANCE STORAGE: Store the RANGER® 250 in clean, dry protected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air. Do this at least once a week in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT: Itʼs nor- mal for the brushes and slip rings to ...
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Lincoln Electric IM919 - page 30
E-1 TROUBLESHOOTING E-1 RANGER® 250 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. CAUTION This Troubleshooting Guide is provided to help you locate and repair pos ...
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Lincoln Electric IM919 - page 31
E-2 TROUBLESHOOTING E-2 RANGER® 250 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS ( ...
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Lincoln Electric IM919 - page 32
E-3 TROUBLESHOOTING E-3 RANGER® 250 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS ( ...
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Lincoln Electric IM919 - page 33
E-4 TROUBLESHOOTING E-4 RANGER® 250 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS ( ...
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Lincoln Electric IM919 - page 34
E-5 TROUBLESHOOTING E-5 RANGER® 250 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS ( ...
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Lincoln Electric IM919 - page 35
F-1 DIAGRAMS F-1 RANGER® 250 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 ...
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Lincoln Electric IM919 - page 36
F-2 DIAGRAMS F-2 RANGER® 250 ...
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Lincoln Electric IM919 - page 37
F-3 DIAGRAMS F-3 RANGER® 250 ...
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Lincoln Electric IM919 - page 38
F-4 DIAGRAMS F-4 RANGER® 250 ...
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Lincoln Electric IM919 - page 39
F-5 DIAGRAMS F-5 RANGER® 250 ...
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Lincoln Electric IM919 - page 40
F-6 DIAGRAMS F-6 RANGER® 250 ...
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Lincoln Electric IM919 - page 41
F-7 DIAGRAMS F-7 RANGER® 250 or s er v ic e t his e qui pm e n t. On l y qualified personnel should install, use Keep away from m oving parts. Keep guards in place. MOVING PART S can injure WA R N I N G Do not touch e lectrically live parts. before servicing. Disconnect NEGATI VE (-) Battery lead Do not operate with panels open. ELECTRIC SH OCK ca ...
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Lincoln Electric IM919 - page 42
F-8 DIAGRAMS F-8 RANGER® 250 ...
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F-9 DIAGRAMS F-9 RANGER® 250 ...
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Lincoln Electric IM919 - page 44
F-10 DIAGRAMS F-10 RANGER® 250 2 9/03 ...
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Lincoln Electric IM919 - page 45
F-11 DIAGRAMS F-11 RANGER® 250 ...
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Lincoln Electric IM919 - page 46
M20333 C CIRCU IT BREAKERS 41.2 0 1046.5 17.5 0 444.5 19.5 0 495.3 TRUC K/U ND ERC ARR IAGE MOU NTING HOLE S 7.22 183.3 24.8 6 631.3 2.62 66.5 23.50 596.9 15.50 393.7 CE NTER OF GR AVITY 29.8 0 756.9 NOTE: CASE F RONT GRAPHI CS MAY NOT MAT CH ALL CODES. 42.1 0 1069.5 20.8 0 528.3 10.2 8 261.0 10.7 8 273.9 33.6 2 854.0 36.2 4 920.4 F-12 DIMENSION PR ...
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Lincoln Electric IM919 - page 47
W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA ...
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Lincoln Electric IM919 - page 48
W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes ...
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Lincoln Electric IM919 - page 49
• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products • ...
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