Lincoln Electric Welder 250 GXT User Manual
RETURN TO MAIN MENU  
IM921-D  
®
February, 2011  
RANGER 250 GXT  
For Machines with Code Number: 11400, 11420, 11493, 11667, 11668, 11736, 11737,  
11792, 11973, 11799, 11800  
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 READ-  
ING THIS MANUAL AND THE  
SAFETY PRECAUTIONS CON-  
TAINED THROUGHOUT. And,  
most importantly, think before  
you act and be careful.  
OPERATOR’S MANUAL  
Copyright © Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ii  
ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases. When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
• AC Welder with Reduced Voltage Control.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and within applicable OSHA PEL and  
ACGIH TLV limits using local exhaust or mechanical  
ventilation. In confined spaces or in some circum-  
stances, outdoors, a respirator may be required.  
Additional precautions are also required when welding  
on galvanized steel.  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5. b. The operation of welding fume control equipment is affected  
by various factors including proper use and positioning of  
the equipment, maintenance of the equipment and the spe-  
cific welding procedure and application involved. Worker  
exposure level should be checked upon installation and  
periodically thereafter to be certain it is within applicable  
OSHA PEL and ACGIH TLV limits.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
5.d. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
5.e. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iii  
iii  
SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
cause fire or explosion.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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.  
process used and properly operating  
regulators designed for the gas and  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact  
can cause overheating and create a fire hazard.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
6.h. Also see item 1.c.  
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available  
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma  
022690-9101.  
6.j. Do not use a welding power source for pipe thawing.  
Refer to http://www.lincolnelectric.com/safety for additional safety information.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iv  
iv  
SAFETY  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
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 lev-  
age, 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.  
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.  
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.  
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.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
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.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
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 ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
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.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
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, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
v
v
for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
CUSTOMER ASSISTANCE POLICY  
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-  
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln  
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-  
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-  
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,  
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or  
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any  
warranty with respect to the sale of our products.  
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control  
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in  
applying these types of fabrication methods and service requirements.  
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com  
for any updated information.  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the  
time the shipment is received.  
Please record your equipment identification information below for future reference. This information can be  
found on your machine nameplate.  
Product _________________________________________________________________________________  
Model Number ___________________________________________________________________________  
Code Number or Date Code_________________________________________________________________  
Serial Number____________________________________________________________________________  
Date Purchased___________________________________________________________________________  
Where Purchased_________________________________________________________________________  
Whenever you request replacement parts or information on this equipment, always supply the information you  
have recorded above. The code number is especially important when identifying the correct replacement parts.  
On-Line Product Registration  
- Register your machine with Lincoln Electric either via fax or over the Internet.  
• For faxing: Complete the form on the back of the warranty statement included in the literature packet  
accompanying this machine and fax the form per the instructions printed on it.  
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then  
“Product Registration”. Please complete the form and submit your registration.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
vi  
vi  
TAbLE OF CONTENTS  
Page  
Installation.......................................................................................................................Section A  
Technical Specifications.......................................................................................................A-1  
Safety Precautions........................................................................................................A-2  
Machine Grounding.......................................................................................................A-2  
Spark Arrester...............................................................................................................A-2  
Towing...........................................................................................................................A-2  
Vehicle Mounting...........................................................................................................A-3  
Pre-Operation Engine Service..............................................................................................A-3  
Fuel, Oil, Battery Connections ......................................................................................A-3  
Welding Cable Connections..........................................................................................A-4  
Angle of Operation ........................................................................................................A-4  
Lifting, Additional Safety Precautions............................................................................A-4  
High Altitude Operation.................................................................................................A-4  
Muffler Outlet Pipe ........................................................................................................A-4  
Location and Ventilation................................................................................................A-5  
Stacking ........................................................................................................................A-5  
Connection of Wire Feeders .........................................................................................A-5  
Connection of Tig Module .............................................................................................A-5  
Additional Safety Precautions .......................................................................................A-5  
Welding Operation Output, Auxiliary Power Receptacles, and Plugs .................................A-6  
Motor Starting and Extension Cord Length Table ................................................................A-6  
Electrical Device Used with the Ranger® 250 GXT..........................................................A-7  
Auxiliary Power While Welding, Standby Power Connections ............................................A-8  
Premises Wiring ...................................................................................................................A-9  
________________________________________________________________________________  
Operation.........................................................................................................................Section b  
Safety Precautions ...............................................................................................................B-1  
General Description..............................................................................................................B-1  
Welder Controls Function and Operation.............................................................................B-1  
Polarity, Range and Control Switch......................................................................................B-2  
Start in/Shutdown Instructions.....................................................................................................B-3  
Starting the Engine........................................................................................................B-3  
Safety Precautions........................................................................................................B-3  
Stopping the Engine......................................................................................................B-3  
Break-In Period .............................................................................................................B-3  
Welding Process ..................................................................................................................B-4  
Stick (Constant Current) Welding..................................................................................B-4  
TIG (Constant Current) Welding ..................................................................................B-4  
Wire Feed Welding Processes (Constant Voltage)......................................................B-4  
Arc Gouging ..................................................................................................................B-4  
Summary of Welding Processes...................................................................................B-5  
________________________________________________________________________________  
Accessories ........................................................................................................Section C  
Optional Equipment...............................................................................................C-1  
Recommended Equipment....................................................................................C-2  
________________________________________________________________________  
Maintenance ....................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
Routine Engine Maintenance ..........................................................................D-1,D2  
Engine Adjustments...............................................................................................D-3  
Slip Rings ..............................................................................................................D-3  
Battery Maintenance.......................................................................................D-3  
Engine Maintenance Parts..............................................................................D-3  
________________________________________________________________________  
Troubleshooting..............................................................................................Section E  
How to Use Troubleshooting Guide.......................................................................E-1  
Troubleshooting Guide...................................................................................E-2, E-3  
________________________________________________________________________  
Wiring Diagrams & Dimension Print..............................................................Section F  
Wiring and Connection Diagrams...................................................................F-1, F-2  
Dimension Print .............................................................................................................F3  
________________________________________________________________________  
Parts List .....................................................................................................P-505, P-634  
________________________________________________________________________  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-1  
TECHNICAL SPECIFICATIONS - Ranger® 250 GXT  
INPUT - GASOLINE ENGINE  
A-1  
INSTALLATION  
( K2382-3, -4 and -5)  
Description  
Operating  
Speed (RPM)  
Displacement  
cu. in.  
(cu.cm.)  
Capacities  
Make/Model  
Starting  
System  
Horsepower  
2 cylinder  
4 Cycle  
Air-Cooled  
Gasoline  
Engine.  
High Idle 3700  
12VDC  
Battery  
Electric Start  
Group 58  
Battery  
Fuel:  
12 Gal (45.4 L)  
Lubricating Oil:  
41.1(674)  
Kohler  
CH23S  
Full Load 3500  
Low Idle 2200  
23 HP @  
3600 RPM  
Aluminum Alloy  
with Cast Iron  
Liners,  
(435 cold  
Cranking  
Amps)  
2.0 Qts. (1.9 L)  
Electronic  
Ignition  
RATED OUTPUT @ 104°F (40°C)- WELDER  
Welding Output  
AC Constant Current 250A / 25V / 100%  
DC Constant Current 250A / 25V / 100%  
DC Constant Voltage 250A / 25V / 100%  
RATED OUTPUT @ 104°F (40°C)- GENERATOR  
Auxiliary Power 1  
10,000 Watts Continuous, 60ꢀHz AC  
11,000 Watts Peak, 60 Hz AC  
120/240 Volts  
RECEPTACLES AND CIRCUIT bREAKERS  
AUXILIARY POWER CIRCUIT bREAKER bATTERY CHARGING CIRCUIT bREAKER  
RECEPTACLES  
(2) 120VAC Duplex (5-20R)  
(1) 120/240VAC Dual Voltage  
Full KVA (14-50R)  
Two 20AMP for Two Duplex Receptacle  
(1) 50AMP for Dual Voltage (2-pole)  
20AMP for Engine Battery  
Charging Circuit  
PHYSICAL DIMENSIONS  
DEPTH  
HEIGHT  
WIDTH  
WEIGHT  
30.00** in.  
762.0 mm  
21.50 in  
42.25 in.  
602 lbs. (273kg)  
546.0 mm  
1073.0 mm  
** Top of enclosure, add 6.00”(152mm) for exhaust.  
ENGINE COMPONENTS  
FUEL SYSTEM  
LUbRICATION  
Full Pressure  
with Full Flow Filter  
5% Regulation  
VALVE LIFTERS  
Hydraulic  
GOVERNOR  
Mechanical Governor  
Mechanical Fuel Pump on K2382-3  
Additional electric fuel lift pump  
on K2382-4, -5.  
AIR CLEANER  
ENGINE IDLER  
MUFFLER  
ENGINE PROTECTION  
Shutdown on low oil  
pressure.  
Low noise Muffler: Top outlet  
can be rotated. Made from  
long life, aluminized steel.  
Dual Element  
Automatic Idler  
1 Output rating in watts is equivalent to volt - amperes at unity factor.Output voltage is within +/-10% at all loads up to rated capacity.  
When welding available auxiliary power will be reduced.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-2  
A-2  
INSTALLATION  
When this welder is mounted on a truck or trailer, it’s  
frame must be electrically bonded to the metal frame  
of the vehicle. Use a #8 or larger copper wire connect-  
ed between the machine grounding stud and the  
frame of the vehicle.  
SAFETY PRECAUTIONS  
WARNING  
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.  
Where this engine driven welder is connected to  
premises wiring such as that in your home or shop, it’s  
frame must be connected to the system earth ground.  
See further connection instructions in the section enti-  
tled “Standby Power Connections”, as well as the arti-  
cle on grounding in the latest National Electrical Code  
and the local code.  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
In general, if the machine is to be grounded, it should  
be connected with a #8 or larger copper wire to a solid  
earth ground such as a metal water pipe going into  
the ground for at least ten feet and having no insulat-  
ed joints, or to the metal framework of a building  
which has been effectively grounded. The National  
Electrical Code lists a number of alternate means of  
grounding electrical equipment. A machine grounding  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
ENGINEꢀEXHAUSTꢀcan kill.  
• Use in open, well ventilated areas or  
vent exhaust outside.  
------------------------------------------------------------------------  
MOVING PARTSꢀcan injure.  
stud marked with the symbol  
front of the welder.  
is provided on the  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
• Keep away from moving parts.  
------------------------------------------------------------------------  
SPARK ARRESTER  
Some federal, state, or local laws may require that  
gasoline engines be equipped with exhaust spark  
arresters when they are operated in certain locations  
where unarrested sparks may present a fire hazard.  
The standard muffler included with this welder does  
not qualify as a spark arrester. When required by local  
regulations, the K1898-1 spark arrester must be  
installed and properly maintained.  
See additional warning information at  
front of this operator’s manual.  
-----------------------------------------------------------  
MACHINE GROUNDING  
Because this portable engine driven welder or genera-  
tor creates it’s own power, it is not necessary to con-  
nect it’s frame to an earth ground, unless the machine  
is connected to premises wiring (your home, shop,  
etc.).  
CAUTION  
An incorrect arrester may lead to damage to the  
engine or adversely affect performance.  
------------------------------------------------------------------------  
TOWING  
WARNING  
The recommended trailer for use with this equipment  
(1)  
for road, in-plant and yard towing by a vehicle is  
To prevent dangerous electric shock, other equip-  
ment to which this engine driven welder supplies  
power must:  
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:  
• be grounded to the frame of the welder using a  
grounded type plug, or be double insulated.  
Do not ground the machine to a pipe that carries  
explosive or combustible material.  
------------------------------------------------------------------------  
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.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-3  
A-3  
INSTALLATION  
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.  
FUEL  
Fill the fuel tank with clean, fresh, lead-free gasoline.  
Observe fuel gauge while filling to prevent overfilling.  
4. Typical conditions of use, i.e., travel speed; rough-  
ness of surface on which the trailer will be operated;  
environmental conditions.  
WARNING  
(1)  
• Damage to the fuel tank may cause  
fire or explosion. Do not drill holes  
in the Ranger® 250 GXT base or  
5. Conformance with federal, state and local laws  
(1) Consult applicable federal, state and local laws regarding specific  
requirements for use on public highways.  
weld to the Ranger® 250 GXT base.  
-----------------------------------------------------------------------  
VEHICLE MOUNTING  
WARNING  
OIL  
Improperly mounted concentrated loads may  
cause unstable vehicle handling and tires or other  
components to fail.  
LUBRICATIONꢀ SYSTEMꢀ CAPACITY  
(INCLUDING ꢀFILTER)  
Kohler CH20S - 2.0 Quarts (1.9 Liters)  
• Only transport this Equipment on serviceable  
vehicles which are rated and designed for such  
loads.  
• Distribute, balance and secure loads so vehicle  
is stable under conditions of use.  
• Do not exceed maximum rated loads for compo-  
nents such as suspension, axles and tires.  
• Mount equipment base to metal bed or frame of  
vehicle.  
The Ranger® 250 GXT is shipped with the engine  
crankcase filled with SAE 10W-30 oil. Check the oil  
level before starting the engine. If it is not up to the full  
mark on the dip stick, add oil as required. Make cer-  
tain that the oil filler cap is tightened securely. Refer to  
the engine Owner’s Manual for specific oil recommen-  
dations.  
• Follow vehicle manufacturer’s instructions.  
------------------------------------------------------------------------  
bATTERY CONNECTIONS  
PRE-OPERATION SERVICE  
CAUTION  
CAUTION  
Use caution as the electrolyte is a strong  
acid that can burn skin and damage eyes.  
READ the engine operating and maintenance  
instructions supplied with this machine.  
------------------------------------------------------------------------  
This welder is shipped with the negative battery cable  
disconnected. Make sure that the Engine Switch is in  
the “STOP” position and attach the disconnected  
cable securely to the negative battery terminal before  
attempting to operate the machine. If the battery is  
discharged and does not have enough power to start  
the engine, see the battery charging instructions in the  
Battery section.  
WARNING  
• Stop engine while fueling.  
• Do not smoke when fueling.  
• Keep sparks and flame away  
from tank.  
• Do not leave unattended while  
fueling.  
• Wipe up spilled fuel and allow  
fumes to clear before starting  
engine.  
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 bat-  
tery with the correct polarity.  
GASOLINE  
can cause fire  
or explosion.  
• Do not overfill tank, fuel expan-  
sion may cause overflow.  
GASOLINE FUEL ONLY  
------------------------------------------------------------------------  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-4  
A-4  
INSTALLATION  
WELDING OUTPUT CAbLES  
ADDITIONAL SAFETY PRECAUTION  
With the engine off, connect the electrode and work  
cables to the studs provided. These connections  
should be checked periodically and tightened if neces-  
sary. Loose connections will result in overheating of  
the output studs.  
WARNING  
• Lift only with equipment of  
adequate lifting capacity.  
• be sure machine is stable  
when lifting.  
When welding at a considerable distance from the  
welder, be sure you use ample size welding cables.  
Listed below are copper cable sizes recommended for  
the rated current and duty cycle. Lengths stipulated  
are the distance from the welder to work and back to  
the welder again. Cable sizes are increased for  
greater lengths primarily for the purpose of minimizing  
cable voltage drop.  
• Do not lift this machine using  
lift bail if it is equipped with a  
heavy accessory such as trail-  
er or gas cylinder.  
FALLING  
• Do not lift machine if lift bail is  
EQUIPMENT can damaged.  
cause injury. • Do not operate machine while  
suspended from lift bail.  
TOTAL COMbINED LENGTH OF  
ELECTRODE AND WORK CAbLES  
------------------------------------------------------------------------  
250 Amps  
100% Duty Cycle  
HIGH ALTITUDE OPERATION  
At higher altitudes, Welder output de-rating may be  
necessary. For maximum rating, de-rate the welder  
output 3.5% for every 1000 ft. (305m) above 3000 ft.  
(914m). If operation will consistently be at altitudes  
above 5,000 ft. (1525m), a carburetor jet designed for  
high altitudes should be installed. This will result in  
better fuel economy, cleaner exhaust and longer  
spark plug life. It will not give increased power.  
Contact your local authorized engine service shop for  
high altitude jet kits that are available from the engine  
manufacturer.  
0-100 Ft. (0-31m)  
1 AWG  
1 AWG  
100-150 Ft. (31-46m)  
150-200 Ft. (46-61m)  
1/0 AWG  
ANGLE OF OPERATION  
Internal combustion engines are designed to run in a  
level condition which is where the optimum perfor-  
mance is achieved. The maximum angle of operation  
for the engine is 15 degrees from horizontal in any  
direction. If the engine is to be operated at an angle,  
provisions must be made for checking and maintain-  
ing the oil at the normal (FULL) oil capacity in the  
crankcase in a level condition.  
CAUTION  
Do not operate with a high altitude jet installed at  
altitudes below 5000 ft. This will result in the  
engine running too lean and result in higher  
engine operating temperatures which can shorten  
engine life.  
------------------------------------------------------------------------  
When operating at an angle, the effective fuel capacity  
will be slightly less than the specified 12 Gal. (45 L).  
MUFFLER OUTLET PIPE  
Using the clamp provided secure the outlet pipe to the  
outlet tube with the pipe positioned such that it will  
direct the exhaust in the desired direction. Tighten  
using a 9/16” socket or wrench.  
LIFTING  
The Ranger® 250 GXT weighs approximately  
685lbs.(411kg) with a full tank of gasoline. A lift bail is  
mounted to the machine and should always be used  
when lifting the machine.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-5  
A-5  
INSTALLATION  
•
Position the “RANGE” switch to the “WIRE FEED  
CV” position.  
Attach the single lead from the LN-25 control box  
to the work using the spring clip on the end of the  
lead - it carries no welding current.  
Place the engine switch in the “AUTO IDLE” posi-  
tion.  
When welding with MIG wire instead of self-  
shielded core wire, weld starts can be improved  
LOCATION / VENTILATION  
The welder should be located to provide an unrestrict-  
ed flow of clean, cool air to the cooling air inlets and to  
avoid heated air coming out of the welder recirculating  
back to the cooling air inlet. Also, locate the welder so  
that engine exhaust fumes are properly vented to an  
outside area.  
•
•
•
STACKING  
by setting the idle mode to “HIGH”  
.
•
Adjust wire feed speed at the LN-25 and adjust  
the welding voltage with the output “CONTROL”  
at the welder.  
Ranger® 250 GXT machines cannot be stacked.  
NOTE: The welding electrode is energized at all  
times, unless an LN-25 with built-in contactor is used.  
If the output “CONTROL” is set below “3”, the LN-25  
contactor may not pull in.  
CONNECTION OF LINCOLN ELECTRIC  
WIRE FEEDERS  
WARNING  
CONNECTION OF THE LN-25 TO THE RANGER®  
250 GXT  
Shut off welder before making any electrical  
connections.  
-----------------------------------------------------------------------  
WIRE FEED (CONSTANT VOLTAGE)  
CONNECTION OF LN-15 ACROSS-THE-ARC WIRE  
FEEDER  
The LN-15 has an internal contactor and the electrode  
is not energized until the gun trigger is closed. When  
the gun trigger is closed the wire will begin to feed and  
the welding process is started.  
•
•
Shut the welder off.  
Connect the electrode cable from the LN-25 to  
the“ELECTRODE” terminal of the welder.  
Connect the work cable to the “TOꢀWORK” termi-  
nal of the welder.  
•
Position the welder “Polarity” switch to the desired  
polarity, either DC (-) or DC (+).  
CONNECTION OF K930-2 TIG MODULE TO THE  
RANGER® 250 GXT.  
• Shut the welder off.  
•
Connect the electrode cable from the LN-15 to  
the“ELECTRODE” terminal of the welder. Connect  
the work cable to the “TOꢀWORK” terminal of the  
welder.  
The TIG Module is an accessory that provides high  
frequency and shielding gas control for AC and DC  
GTAW (TIG) welding. See IM528 supplied with the  
TIG Module for installation instructions.  
• Set the Polarity switch to the desired polarity, either  
DC (-) or DC (+).  
Note: The TIG Module does not require the use of a  
high frequency bypass capacitor. However, if the  
Ranger® 250 GXT is used with any other high fre-  
quency equipment, the bypass capacitor must be  
installed, order kit T12246.  
• Attach the single lead from the front of the LN-15  
to work using the spring clip at the end of the lead.  
This is a control lead to supply current to the wire  
feeder motor; it does not carry welding current.  
• Set the “RANGE” switch to the “WIREꢀFEED-CV”  
position  
• Place the Engine switch in the “Auto Idle” position  
when welding with MIG wire instead of self-shielded  
core wire, weld starts can be improved by setting  
the idle mode to “HIGH”.  
• Adjust the wire feed speed at the LN-15 and adjust  
the welding voltage with the output “CONTROL” at  
the welder. Output “CONTROL” must be set above 3  
when welding with MIG wire instead of self-shielded  
core wire, weld starts can be improved by setting  
INSTRUCTIONS  
ADDITIONAL SAFETY PRECAUTIONS  
Always operate the welder with the roof and case  
sides in place as this provides maximum protection  
from moving parts and assures proper cooling air flow.  
Read and understand all Safety Precautions before  
operating this machine. Always follow these and any  
other safety procedures included in this manual and in  
the Engine Owner’s Manual.  
the idle mode to “HIGH”  
.
Note: LN-15 Control Cable model will not work with  
the Ranger® 250 GXT.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-6  
A-6  
INSTALLATION  
WELDER OPERATION  
WELDER OUTPUT  
120/240 VOLT DUAL VOLTAGE RECEPTACLE  
• Maximum Open Circuit Voltage at 3700 RPM is  
80 Volts RMS.  
The 120/240 volt receptacle can supply up to 42  
amps of 240 volt power to a two wire circuit, up to 42  
amps of 120 volts power from each side of a three  
wire circuit (up to 84 amps total). Do not connect the  
120 volt circuits in parallel. Current sensing for the  
automatic idle feature is only in one leg of the three  
wire circuit as shown in the following column.  
• Duty Cycle is the percentage of time the load is  
being applied in a 10 minute period. For example, a  
60% duty cycle represents 6 minutes of load and 4  
minutes of no load in a 10 minute period. Duty  
Cycle for the Ranger® 250 GXT is 100%.  
Ranger® 250 GXT  
GND  
Constant Current  
250 Amps AC @ 25 Volts  
250 Amps DC @ 25 Volts  
Constant Voltage  
250 Amps DC @ 25 Volts  
AUXILIARY POWER  
120 V  
The Ranger® 250 GXT can provide up to 10,000  
watts of 120/240 volts AC, single phase 60Hz power  
for continuous use, and up to 11,000 watts of 120/240  
volts AC, single phase 60Hz power peak use. The  
front of the machine includes three receptacles for  
connecting the AC power plugs; one 50 amp 120/240  
volt NEMA 14-50R receptacle and two 20 amp 120  
volt NEMA 5-20R receptacles. Output voltage is within  
+/-10% at all loads up to rated capacity.  
240 V  
120 V*  
*Current Sensing for Automatic Idle.  
(Receptacle viewed from front of Machine)  
120 V DUPLEX RECEPTACLES  
The 120V auxiliary power receptacles should only be  
used with three wire grounded type plugs or approved  
double insulated tools with two wire plugs.  
All auxiliary power is protected by circuit breakers. the  
120V has 20 Amp circuit breakers for each duplex  
receptacle. The 120/240V Single Phase has a 50 Amp  
2-pole Circuit Breaker that disconnects both hot leads  
simultaneously.  
The current rating of any plug used with the system  
must be at least equal to the current load through the  
associated receptacle.  
CAUTION  
MOTOR STARTING  
Do not connect any plugs that connect to the  
power receptacles in parallel.  
Most 1.5 hp AC single phase motors can be started if  
there is no load on the motor or other load connected  
to the machine, since the full load current rating of a  
1.5 hp motor is approximately 20 amperes (10  
amperes for 240 volt motors). The motor may be run  
at full load when plugged into only one side of the  
duplex receptacle. Larger motors through 2 hp can be  
run provided the receptacle rating as previously stated  
is not exceeded. This may necessitate 240V operation  
only.  
------------------------------------------------------------------------  
Start the engine and set the “IDLER” control switch to  
the desired operating mode. Set the “CONTROL” to  
10. Voltage is now correct at the receptacles for auxil-  
iary power.  
Ranger® 250 GXT Extension Cord Length Recommendations  
(Use the shortest length extension cord possible sized per the following table.)  
Current Voltage Load  
(Amps) Volts (Watts)  
Maximum Allowable Cord Length in ft. (m) for Conductor Size  
12 AWG  
40 (19)  
30 (9)  
75 (23)  
60 (18)  
14 AWG  
30 (9)  
10 AWG  
8 AWG  
6 AWG  
4 AWG  
15  
20  
15  
20  
42  
120  
120  
240  
240  
240  
1800  
2400  
3600  
4800  
10,000  
75 (23) 125 (38) 175 (53)  
300 (91)  
225 (69)  
600 (183)  
450 (137)  
225 (69)  
50 (15)  
88 (27) 138 (42)  
150 (46) 225 (69) 350 (107)  
175 (53) 275 (84)  
50 (15) 90 (27) 150 (46)  
60 (18)  
100 (30)  
Conductor size is based on maximum 2.0% voltage drop.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-7  
A-7  
INSTALLATION  
TABLE lll  
ELECTRICAL DEVICE USE WITH THE Ranger® 250 GXT.  
Type  
Common Electrical Devices  
Possible Concerns  
Resistive  
Heaters, toasters, incandescent  
light bulbs, electric range, hot  
pan, skillet, coffee maker.  
NONE  
Capacitive  
TV sets, radios, microwaves,  
appliances with electrical control.  
Voltage spikes or high voltage  
regulation can cause the capaci-  
tative elements to fail. Surge  
protection, transient protection,  
and additional loading is recom-  
mended for 100% fail-safe oper-  
ation. DO NOT RUN THESE  
DEVICES WITHOUT ADDI-  
TIONAL RESISTIVE TYPE  
LOADS.  
Inductive  
Single-phase induction motors,  
drills, well pumps, grinders, small  
refrigerators, weed and hedge  
trimmers  
These devices require large  
current inrush for starting.  
Some synchronous motors may  
be frequency sensitive to attain  
maximum output torque, but  
they SHOULD BE SAFE from  
any frequency induced failures.  
Capacitive/Inductive  
Computers, high resolution TV sets,  
complicated electrical equipment.  
An inductive type line condition-  
er along with transient and  
surge protection is required, and  
liabilities still exist. DO NOT  
USE THESE DEVICES WITH A  
Ranger® 250 GXT  
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected  
to the Ranger® 250 GXT.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-8  
A-8  
INSTALLATION  
1. Install a double pole, double throw switch between  
the power company meter and the premises  
disconnect.  
AUXILIARY POWER WHILE WELDING  
Simultaneous welding and power loads are permitted  
by following Table I. The permissible currents shown  
assume that current is being drawn from either the  
120V or 240V supply (not both at the same time).  
Also, the “Output Control” is set at “10” for maximum  
auxiliary power.  
Switch rating must be the same or greater than  
the customer’s premises disconnect and service  
overcurrent protection.  
2. Take necessary steps to assure load is limited to  
the capacity of the Ranger® 250 GXT by installing  
a
50 amp 240V double pole circuit breaker.  
Maximum rated load for the 240V auxiliary is 42  
amperes. Loading above 42 amperes will reduce  
output voltage below the allowable -10% of rated  
voltage which may damage appliances or other  
motor-driven equipment.  
TAbLE I  
SIMULTANEOUS WELDING AND POWER  
Output Selector  
Setting  
Permissible Power  
Watts (Unity Power  
Factor)  
Permissible Auxiliary  
Current in Amperes  
@ 120V *-or- @ 240V  
Max. Stick or Wire  
Feed Setting  
None  
5100  
0
0
3. Install a 50 amp 120/240V plug (NEMA type 14-50)  
to the Double Pole Circuit Breaker using No. 8,  
4 conductor cable of the desired length. (The  
50 amp 120/240V plug is available in the  
optional plug kit.)  
180 Stick Setting  
130 Stick Setting  
80 Stick Setting  
No Welding  
42  
21  
7200  
8750  
60**  
72**  
84**  
30  
36  
42  
4. Plug this cable into the 50 amp 120/240V  
receptacle on the Ranger® 250 GXT case front.  
10,000  
* Each duplex receptacle is limited to 20 amps.  
**Not to exceed 50A per 120VAC branch circuit when  
splitting the 240 VAC output.  
STANDbY POWER CONNECTIONS  
The Ranger® 250 GXT is suitable for temporary,  
standby, or emergency power using the engine manu-  
facturer’s recommended maintenance schedule.  
The Ranger® 250 GXT can be permanently installed  
as a standby power unit for 240V-3 wire, single phase  
42 ampere service.  
WARNING  
(Connections must be made by a licensed electri-  
cian who can determine how the 120/240V power  
can be adapted to the particular installation and  
comply with all applicable electrical codes.) The  
following information can be used as a guide by  
the electrician for most applications (refer also to  
the connection diagram shown in Figure 1.)  
------------------------------------------------------------------------  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-9  
A-9  
INSTALLATION  
Figure 1  
CONNECTION OF Ranger® 250 GXT TO PREMISES WIRING  
WARNING  
Connection of Ranger® 250 GXT to premises  
wiring must be done by a licensed electrician and  
must comply with the National Electrical Code and  
all other applicable electrical codes.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-1  
b-1  
OPERATION  
SAFETY PRECAUTIONS  
WELDER CONTROLS - FUNCTION AND  
OPERATION  
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.  
ENGINE SWITCH  
The engine switch is used to Start the Engine, Select  
High Idle or Auto Idle while the engine is running, and  
stop the Engine.  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
When placed in the “OFF”  
circuit is de-energized to shut down the engine.  
position, the ignition  
When held in the “START”  
starter motor is energized.  
position, the engine  
• Always wear dry insulating gloves.  
• Always operate the welder with the hinged door  
closed and the side panels in place.  
When in “HIGH IDLE” (  
run continuously at high idle.  
) position, the engine will  
• Read carefully the Safety Precautions page  
before operating this machine. Always follow  
these and any other safety procedures included  
in this manual and in the Engine Instruction  
Manual.  
When in “AUTO IDLE” (  
engine will run continuously and the idler operates as  
follows:  
/
) position, the  
•
Welding  
------------------------------------------------------------------------  
When the electrode touches the work, the welding  
arc is initiated and the engine accelerates to full  
speed.  
GENERALꢀDESCRIPTION  
The Ranger® 250 GXT is a twin-cylinder, gasoline dri-  
ven, multiprocess arc welder and AC power genera-  
tor. It is built in a heavy gauge steel case for durability  
on the job site.  
After welding ceases (and no auxiliary power is  
being drawn), the engine will return to low idle  
after approximately 10 to 14 seconds.  
Codes 11792 and above meet EPA evaporative emis-  
sion requirements.  
•
Auxiliary Power  
With the engine running at low idle and auxiliary  
power for lights or tools is drawn (approximately  
100-150 watts or greater) from the receptacles,  
the engine will accelerate to high speed. ꢀIf no  
power is being drawn from the receptacles (and  
not welding) for 10-14 seconds, the idler reduces  
the engine speed to low idle.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-2  
“
b-2  
OPERATION  
6-PIN CONNECTOR  
RANGE” SWITCH  
For attaching optional remote control equipment.  
The “Range” switch is used to select one of four  
amperage ranges with generous overlap for Stick/TIG  
welding, or one Wire Feed welding range.  
LOCAL / REMOTE CONTROL SWITCH  
(See Accessory Section For “K” numbers)  
Process  
Range Setting  
Current Range  
STICK/TIG  
(constant current)  
(4 range settings)  
80 Max.  
130 Max.  
180 Max.  
250 Max.  
50 to 80 Amps  
70 to 130 Amps  
110 to 180 Amps  
160 to 250 Amps  
The toggle switch on the control panel labeled  
"LOCAL" and "REMOTE" provides the option of con-  
trolling the welding output at the control panel or  
remotely. Remote connections are made at the 6-pin  
connector. For control at the control panel set the  
switch in the "LOCAL" position.  
WIRE FEED  
(constant voltage)  
(2 range setting)  
14 to 22V  
18 to 28V  
Up to 250 Amps  
For remote control set the switch in the "REMOTE"  
position.  
CAUTION  
Never change the “RANGE” Switch setting while  
welding. This will damage the switch.  
------------------------------------------------------------------------  
“
CONTROL” DIAL  
Provides a fine welding current adjustment within the  
Range Switch settings in the STICK mode and weld-  
ing voltage control with the Range switch set in the  
wire feed mode.  
POLARITY SWITCH  
Provides three selectable welding polarities:  
AC, DC+ & DC-  
CAUTION  
Never change the Polarity switch setting while  
welding. This will damage the switch.  
------------------------------------------------------------------------  
RANGER® 250 GXT APPROXIMATE FUEL CONSUMPTION  
KOHLER  
23 H.P. COMMAND  
.40 Gallons/Hour  
(1.50 Liters/Hour)  
.77 Gallons/Hour  
(2.91 Liters/Hour)  
1.27 Gallons/Hour  
(4.82 Liters/Hour)  
1.50 Gallons/Hour  
(5.69 Liters/Hour)  
1.41 Gallons/Hour  
(5.33 Liters/Hour)  
1.48 Gallons/Hour)  
(5.62 Liters/Hour)  
Low Idle - No Load  
2400 RPM  
High Idle - No Load  
3700 RPM  
AC CC Weld Output  
250 Amps @ 25 Volts  
DC CC Weld Output  
250 Amps @ 25 Volts  
DC CV Weld Output  
250 Amps @ 25 Volts  
Auxiliary Power  
10,000 Watts  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-3  
b-3  
OPERATION  
STOPPING THE ENGINE  
STARTING/SHUTDOWN INSTRUCTIONS  
STARTING THE ENGINE  
Remove all welding and auxiliary power loads and  
allow engine to run at low idle speed for a few minutes  
to cool the engine.  
WARNING  
• Do not touch electrically live parts  
of electrode with skin or wet  
clothing.  
Stop the engine by placing the Engine switch in the  
“OFF”  
position.  
A fuel shut off valve is not required on the Ranger®  
250 GXT because the fuel tank is mounted below the  
engine.  
• Keep flammable material away.  
bREAK-IN PERIOD  
• Insulate yourself from work and  
ground. Wear eye, ear, and body  
protection.  
It is normal for any engine to use a greater amount of  
oil until the break-in is accomplished. Check the oil  
level twice a day during the break-in period (approxi-  
mately 50 running hours).  
• Keep your head out of the fumes.  
• Use ventilation or exhaust to  
remove fumes from breathing zone.  
IMPORTANT: IN ORDER TO ACCOMPLISH THIS  
bREAK-IN, THE UNIT SHOULD bE  
SUbJECTED TO MODERATE  
LOADS, WITHIN THE RATING OF  
THE MACHINE. AVOID LONG IDLE  
RUNNING PERIODS. REMOVE  
Be sure all Pre-Operation Maintenance has been per-  
formed. Also, read the Engine Owner’s Manual before  
starting for the first time.  
LOADS AND ALLOW ENGINE TO  
COOL bEFORE SHUTDOWN.  
Remove all loads connected to the AC power recepta-  
cles. Use the choke control as follows:  
The engine manufacturer’s recommendation for the  
running time until the first oil change is as follows:  
KOHLER ENGINE - Always pull the choke control out  
when starting the engine; cold, warm or hot.  
KOHLER  
CH23S  
Turn the engine switch to the “start”  
position and  
crank the engine until it starts. Release the switch as  
soon as the engine starts, slowly return the choke  
control to the full “in” position (choke open),  
5 HRS  
and turn the switch to the Auto Idle(  
/
)
position. Do not turn the switch to the “start” position  
while the engine is running because this will cause  
damage to the ring gear and/or starter motor  
The oil filter is to be changed at the second oil  
change. Refer to the Engine Owner’s Manual for more  
information.  
After running at high engine speed for 10-14 seconds,  
the engine will go to low idle.  
Allow the engine to warm up by letting it run at low idle  
for a few minutes.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-4  
b-4  
OPERATION  
SETTINGSꢀFORꢀ 1% THORIATED TUNGSTEN  
WELDING PROCESS  
For any electrodes the procedures should be kept  
within the rating of the machine. For electrode infor-  
mation see the appropriate Lincoln publication.  
TUNGSTEN  
DIAMETER (in.)  
RANGEꢀSWITCH  
SETTINGS  
APPROXIMATE  
CURRENTꢀRANGE  
1/8  
3/32  
1/16  
80, 130, or 180  
80 or 130  
80  
80 - 225 Amps  
50 - 180 Amps  
45 - 120 Amps  
STICK (CONSTANT CURRENT) WELDING  
put currents on each range setting will be approxi-  
mately 50% higher than those marked on the name-  
plate. This is due to the special nature of the AC TIG  
welding arc. Do not AC TIG weld on the 250 Amp set-  
ting. The output may exceed the rating of the  
Ranger® 250 GXT.  
Connect welding cables to the "TOꢀWORK” and  
"ELECTRODE” studs. Start the engine. Set the  
"Polarity” switch to the desired polarity. The “RANGE”  
switch markings indicate the maximum current for that  
range as well as the typical electrode size for that  
range. The “OUTPUT” Control provides fine adjust-  
ment of the welding current within the select range.  
For maximum output within a selected range set the  
“OUTPUT” Control at 10. For minimum output within a  
selected range set the “OUTPUT” Control at 5. (“OUT-  
PUT” Control settings below 5 may reduce arc stabili-  
ty) For best overall welding performance set the  
“RANGE” Switch to the lowest setting and the OUT-  
PUT” Control near the maximum to achieve the  
desired welding current.  
WIRE FEED WELDING PROCESSES  
(CONSTANT VOLTAGE)  
® electrode recommended for use with  
The Innershield  
the Ranger® 250 GXT is NR®-211-MP. The electrode  
sizes and welding ranges that can be used with the  
Ranger® 250 GXT are shown in the following table:  
The Ranger® 250 GXT is recommended for limited  
Diameter  
(in.)  
Wire Speed  
Range In./Min.  
Approximate  
Current Range  
RANGE SETTING  
TYPICAL  
CURRENT RANGE  
.035  
.045  
.068  
5/64  
80 - 110  
70 - 130  
40 - 90  
50 - 75  
75A to 120A  
120A to 170A  
125A to 210A  
180A to 235A  
ELECTRODE SIzE  
80 MAX.  
130 MAX.  
180 MAX.  
250 MAX.  
3/32  
1/8  
50 TO 80 AMPS  
70 TO 130 AMPS  
110 TO 180 AMPS  
160 TO 250 AMPS  
“MIG” welding (GMAW - gas metal arc welding). The  
recommended electrodes are .030” and .035” L-50  
and L-56. They must be used with a blended shield-  
ing gas such as C25 (75% Argon - 25% CO2). The  
5/32  
3/16  
The Ranger® 250 GXT can be used with a broad  
range of AC and DC stick electrodes. See “Welding  
Tips 1” included with the Ranger® 250 GXT for elec-  
trodes within the rating of this unit and recommended  
welding currents of each.  
welding ranges that can be used with the Ranger®  
250 GXT are shown in the following table:  
Diameter  
(in.)  
Wire Speed  
Range In./Min.  
Approximate  
Current Range  
TIG (CONSTANT CURRENT) WELDING  
.030  
.035  
.045  
75 - 300  
100 - 250  
125 - 200  
50A to 130A  
80A to 175A  
145A to 200A  
The Ranger® 250 GXT can be used in a wide variety of AC and  
DC Tungsten Inert Gas (TIG) welding applications for AC TIG  
Welding up to 200 amps and DC TIG welding up to 250 amps.  
ARC GOUGING  
The K930 [ ] TIG Module installed on a Ranger® 250 GXT pro-  
vides high frequency and shielding gas control for AC and DC  
GTAW (TIG) welding processes. The TIG Module allows full  
range output control.  
The Ranger® 250 GXT can be used for limited arc  
gouging.  
Set the Range switch to adjust output current to the  
desired level for the gouging electrode being used  
according to the ratings in the following table:  
When using the Ranger® 250 GXT for AC TIG welding of alu-  
minum the following settings and electrodes are recommended:  
For AC TIG Welding, the maximum TIG Welding out-  
ELECTRODE SETTING  
CURRENT RANGE (DC, electrode positive)  
SETTINGSꢀFORꢀPUREꢀTUNGSTEN  
1/8  
5/32  
3/16  
30 - 60 Amps  
90 - 150 Amps  
150 - 250 Amps  
TUNGSTEN  
DIAMETER (in.)  
RANGEꢀSWITCH  
SETTINGS  
APPROXIMATE  
CURRENTꢀRANGE  
1/8  
3/32  
1/16  
80 or 130  
100 - 300 Amps  
45 - 140 Amps  
45 - 100 Amps  
80  
80  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-5  
b-5  
OPERATION  
SUMMARY OF WELDING PROCESSES  
CONTROL  
CAbLE  
USED  
ELECTRODE  
WHEN NOT  
WELDING  
IDLE  
MODE  
TO START  
WELDING  
PROCESS  
STICK  
No  
No  
AUTO  
AUTO  
Hot  
Touch electrode to work.  
Welding starts immediately  
and engine goes to high  
idle.  
WIREꢀFEED, LN-25 WITH  
INTERNALꢀCONTACTOR  
Cold  
Press gun trigger, LN-25  
contactor closes. Welding  
starts immediately and  
engine goes to high idle.  
Note: Output Control  
must be set above “3”.*  
TIG, TIG MODULE WITH  
WITHꢀCONTACTORꢀKIT  
CONTROLꢀCABLE, &  
AMPTROL  
Yes  
No  
HIGH  
Cold  
Cold  
Press Amptrol,  
contactor closes,  
welding starts immediately.  
WIRE FEED, LN-15  
ACROSS the ARC  
(has internal contactor)  
AUTO  
Press gun trigger.  
LN-15 contactor closes,  
Welding starts immediately  
and engine goes to “HIGH”  
Idle.  
Note: Output Control must  
be set above “3”.*  
*When welding with MIG wire instead of self-shielded  
core wire, weld starts can be improved by setting the  
idle mode to “HIGH”  
.
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-1  
C-1  
ACCESSORIES  
OPTIONAL EQUIPMENT (Field Installed)  
K875 Accessory Kit - For Stick welding. Includes  
20ft.(6.1m)#6 electrode cable with lug. 15ft.(4.6m)#6 work  
cable with lugs, headshield, filter plate, work clamp, elec-  
trode holder and sample pack of mild steel electrode. 150  
amp capacity.  
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.)  
K1898-1 Spark Arrester Kit - Attaches between muffler  
and exhuast elbow. Virtually eliminates spark emissions.  
Order K957-1 Trailer  
K958-1 Ball Hitch  
K958-2 Lunette Eye Hitch  
K959-2 Fender & Light Kit  
K965-1 Cable Storage Rack  
K1690-1 GFCI RECEPTACLE KIT - Includes one UL  
approved120V 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 limit-  
ed to the 20 Amps. Two kits are required.  
K1737-1 FOUR WHEEL ALL-TERRAIN UNDER-  
CARRIAGE - For moving by hand at construction  
sites. Heavy duty puncture resistant pneumatic tires.  
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 undercar-  
riage with the installation of K1745-1 Cylinder  
Holder(s). Heavy duty puncture resistant pneumatic  
tires and front caster.  
K1816-1 FULL KVA ADAPTER KIT - Plugs into the  
120/240V NEMA 14-50R receptacle on the case front  
(which accepts 4-prong plugs) and converts it to a NEMA 6-  
50R receptacle, (which accepts 3-prong plugs.)  
T12153-9 Full-KVA Power Plug - One dual voltage plug  
rated at 120/240V, 50 amps.  
K1745-1 WELDING GAS CYLINDER LPG TANK  
HOLDER  
Holds Welding Gas Cylinder for use on K1770-1  
Undercarriage. One or two may be installed on an  
undercarriage.  
K1788-1 ROLL CAGE - Gives added damage protection.  
Attaches to K1737-1, K1770-1, and K957-1.  
K886-2 Canvas Cover -To protect the Ranger® 250  
GXT when not in use. Made from attractive red can-  
vas material which is flame retardant, mildew resis-  
tant, and water repellent.  
K802R Power Plug Kit - provides four 120V plugs  
rated at 15 amps each and one dual voltage, Full  
KVA plug rated at 120/240V, 50 amps.  
K802N Power Plug Kit - Provides four 120V plugs  
rated at 20 amps each and one dual voltage, full KVA  
plug rated at 120/240V, 50 amps.  
K857 (25 ft.(7.5m) or K857-1(100 ft.(30.4m)  
Remote Control- Portable control provides same dial range  
as the output control on the welder. Has a convenient 6-pin  
plug for easy connection to the welder.  
K704 Accessory Kit - Includes 35 ft (10.7m) 2/0 AWG elec-  
trode cable, 30 ft. (9.1m) 2/0 AWG work cable, headshield  
with No. 12 filter, GC300 work clamp and Cooltong® 300  
electrode holder. Cables are rated at 300 amps, 100% duty  
cycle.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-2  
C-2  
ACCESSORIES  
RECOMMENDEDꢀEQUIPMENT  
Optional TIG Equipment:  
STICK  
K939-1 Docking Kit - For Mounting the K930-2 TIG Module  
on top of the Ranger® 250 GXT.  
K704 Accessory Kit- (400 AMP Capacity) which  
includes:  
K937-45 Control Cable Extension - Allows TIG Module to be  
operated at distances up to 200ft. from the power source.  
Available in 45ft. (13.7m).  
• Electrode Holder & Cable  
• Work Clamp & Cable  
• Headshield  
K963-3 Hand Amptrol  
K875 Accessory Kit- (150 AMP Capacity)  
K870  
Foot Amptrol  
WIREꢀFEED  
REMOTE OUTPUT CONTROL  
(See Operations Section for reference)  
K449 LN-25 - Includes internal contactor for across  
the arc operation (no control cable). Provides “cold”  
electrode until gun trigger is pressed. Includes gas  
solenoid.  
The Ranger® 250 GXT is equipped with a 6-pin connector.  
The 6- pin connector is for connecting the K857 or K857-1  
Remote Control (optional) or for TIG welding, the K870 Foot  
Amptrol or the K963-3 Hand Amptrol. When remote con-  
trol is used set the LOCAL / REMOTE switch in the  
"REMOTE" position.  
Magnum Gun and Magnum Gun Connector Kit are  
required for gas-shielded welding. Innershield Gun is  
required for gasless welding.  
Plasma  
K1580-1 Pro-Cut 55  
(Requires Full KVA Adapter K1816-1)  
K126-2 Magnum 350 Innershield Gun  
K1802-1 Magnum 300 MIG Gun (for LN-25)  
K470-2 Magnum 300 MIG Gun (for LN-15)  
K466-10 Connector Kit (for LN-15, K470-2)  
K1500-1 Gun Receiver Bushing (for LN-15 & K126-2)  
K1870-1 LN-15 Across the Arc Model  
TIG  
Magnum™ TIG Torch  
K1783-4 - TIG Torch  
Magnum Parts Kit and Argon Gas  
K930-2 TIG Module - Provides high frequency and shield-  
ing gas control.for AC and DC GTAW (TIG) welding applica-  
tions. Its compact case is designed foe easy carrying, com-  
plete with a handle. High frequency bypass is built in  
Requires K938-1 Contactor Kit, K936-3 Control Cable, and  
K814 Arc Start Switch.  
K938-1 Contactor Kit - For use with TIG Module, Provides a  
“cold” electrode until the triggering device (Arc Start Switch)  
is pressed.  
K936-3 Control Cable - Connects TIG Module to Ranger®  
250 GXT.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-1  
D-1  
MAINTENANCE  
SAFETY PRECAUTIONS  
CAUTION  
WARNING  
Make certain that the oil filler cap is securely tight-  
ened after checking or adding oil. If the cap is not  
tight, oil consumption can increase significantly  
which may be evidenced by white smoke coming  
from the exhaust.  
Have qualified personnel do the maintenance  
work. Turn the engine off before working inside  
the machine. In some cases, it may be necessary  
to remove safety guards to perform required  
maintenance. Remove guards only when  
necessary and replace them when the mainte-  
nance requiring their removal is complete.  
Always use the greatest care when working near  
moving parts.  
• OIL - Maintenance schedule for changing the oil and  
oil filter after break-in :  
Kohler  
CH23S  
Do not put your hands near the engine cooling  
blower fan. If a problem cannot be corrected by  
following the instructions, take the machine to  
the nearest Lincoln Field Service Shop.  
Oil  
100 Hrs.  
Oil Filter  
200 Hrs.  
-----------------------------------------------------------------------  
The above schedule is for normal operating condi-  
tions. More frequent oil changes are required with  
dusty, high temperature and other severe operating  
conditions. Refer to the maintenance section of the  
Engine Owner's Manual for more information.  
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.  
-----------------------------------------------------------------------  
NOTE: Engine life will be reduced if the oil and oil  
filter are not changed according to the manufacturer’s  
recommendation.  
ENGINEꢀEXHAUSTꢀcan kill.  
• Use in open, well ventilated areas  
or vent exhaust outside.  
ENGINE OIL CHANGE  
Drain the oil while the engine is warm to assure rapid  
and complete draining.  
-----------------------------------------------------------------------  
MOVING PARTSꢀcan injure.  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
• Keep away from moving parts.  
-----------------------------------------------------  
• Remove the oil filler cap and dipstick. Remove the  
yellow cap from the oil drain valve and attach the  
flexible drain tube supplied with the machine. Push  
in and twist the drain valve counterclockwise. Pull  
the valve out and drain the oil into a suitable contain-  
er.  
------------------  
See additional warning information  
throughout this operator’s manual and  
the Engine manual as well.  
• Close the drain valve by pushing in and twisting  
clockwise. Replace the yellow cap.  
-----------------------------------------------------------------------  
• Refill to the upper limit mark on the dipstick with the  
recommended oil. Tighten the oil filler cap securely.  
Read the Safety Precautions in the front of this manual  
and the engine instruction manual before working on  
this machine.  
ENGINE OIL REFILL CAPACITIES  
Without oil filter replacement:  
• 1.7qt. (1.6 liter)-Kohler  
Keep all equipment safety guards, covers, and devices  
in position and in good repair. Keep hands, hair, cloth-  
ing, and tools away from gears, fans, and all other  
moving parts when starting, operating, or repairing the  
equipment.  
With oil filter replacement:  
• 2.0qt. (1.9 liter)-Kohler  
Routine Maintenance  
•
At the end of each day’s use, refill the fuel tank to  
minimize moisture condensation in the tank.  
Running out of fuel tends to draw dirt into the fuel  
system. Also, check the crankcase oil level and  
add oil if indicated.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-2  
D-2  
MAINTENANCE  
Use 4-stroke motor oil that meets or exceeds the  
requirements for API service classification SG or SH.  
Always check the API SERVICE label on the oil con-  
tainer to be sure it includes the letters SG or SH.  
AIR CLEANER AND OTHER MAINTENANCE  
•
Air Cleaner - With normal operating conditions, the  
maintenance schedule for cleaning and re-oiling  
the foam pre-filter is every 25 hours and replace-  
ment of the air cleaner filter every 100 hours.  
More frequent servicing is required with dusty  
operating conditions. Refer to the maintenance  
section of the Engine Owner’s Manual for more  
information.  
SAE 10W-30 is recommended for general, all-tempera-  
ture use, -5 F to 104 F (-20 C to 40 C).  
See Engine Owner’s Manual for more specific informa-  
tion on oil viscosity recommendations.  
Wash your hands with soap and water after handling  
used oil.  
•
•
Refer to the maintenance section of the Engine  
Owner’s Manual for the maintenance schedule,  
spark plug servicing, cooling system servicing, and  
fuel filter replacement.  
Please dispose of used motor oil in a manner that is  
compatible with the environment. We suggest you take  
it in a sealed container to your local service station or  
recycling center for reclamation.  
Blow out the machine with low pressure air period-  
ically. In particularly dirty locations, this may be  
required once a week.  
Do not throw it in the trash, pour it on the ground or  
down a drain.  
• Output Ranger Selector and Polarity Switches:  
Switch contacts should not be greased. To keep  
contacts clean, rotate the switch through its entire  
range frequently. Good practice is to turn the han-  
dle from maximum to minimum setting twice each  
morning before starting to weld.  
OIL FILTER CHANGE  
1. Drain the engine oil.  
2. Remove the oil filter, and drain the oil into a suitable  
container. Discard the used oil filter.  
3. Clean the filter mounting base, and coat the gasket  
of the new oil filter with clean engine oil.  
4. Screw on the new oil filter by hand, until the gasket  
contacts the filter mounting base, then use an oil fil-  
ter socket tool to tighten the filter an additional 1/2 to  
7/8 turn.  
5. Refill the crankcase with the specified amount of the  
recommended oil. Reinstall the oil filler cap.  
6. Start the engine and check for oil filter leaks.  
7. Stop the engine, and check the oil level. If neces-  
sary, add oil to the upper limit mark on the dipstick.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-3  
D-3  
MAINTENANCE  
ENGINE ADJUSTMENTS  
WARNING  
GASES FROMꢀbATTERY can explode.  
• Keep sparks, flame and cigarettes away from battery.  
OVERSPEED IS HAzARDOUS  
To prevent EXPLOSION when:  
• INSTALLINGꢀAꢀNEWꢀbATTERY - disconnect negative  
cable from old battery first and connect to new bat-  
tery last.  
WARNING  
The maximum allowable high idle speed for this  
machine is 3750 RPM, no load. Do NOT tamper  
with governor components or setting or make any  
other adjustments to increase the maximum  
speed. Severe personal injury and damage to the  
machine can result if operated at speeds above  
maximum.  
-----------------------------------------------------------------------  
Adjustments to the engine are to be made only by a  
Lincoln Service Center or an authorized Field Service  
Shop.  
• CONNECTINGꢀAꢀbATTERYꢀCHARGER - Remove bat-  
tery from welder by disconnecting negative cable  
first, then positive cable and battery clamp. When  
reinstalling, connect negative cable last. Keep well  
ventilated.  
• USINGꢀAꢀbOOSTER - connect positive lead to battery  
first then connect negative lead to engine foot.  
bATTERYꢀACIDꢀCANꢀbURNꢀEYESꢀANDꢀSKIN.  
• Wear gloves and eye protection and be careful when  
working near battery. Follow instructions printed on  
battery.  
bATTERY  
SLIP RINGS  
1. When replacing, jumping, or otherwise connecting  
the battery to the battery cables, the proper  
polarity must be observed. Failure to observe  
the proper polarity could result in damage to the  
charging circuit. The positive (+) battery cable  
has a red terminal cover.  
2. If the battery requires charging from an external  
charger, disconnect the negative battery cable  
first and then the positive battery cable before  
attaching the charger leads. Failure to do so  
can result in damage to the internal charger  
components. When reconnecting the cables,  
connect the positive cable first and the negative  
cable last.  
A slight amount of darkening and wear of the slip rings  
and brushes is normal. Brushes should be inspected  
when a general overhaul is necessary.If brushes are  
to be replaced, clean slip rings with a fine emery  
paper.  
CAUTION  
Do not attempt to polish slip rings while engine is  
running.  
-----------------------------------------------------------------------  
HARDWARE  
Both English and Metric fasteners are used in this  
welder.  
ENGINE MAINTENANCE PARTS  
KOHLERꢀC23S  
Oil Filter  
KOHLER 12 050 01  
FRAM PH8172*  
Air Filter  
Element  
KOHLER 47 083 03  
FRAM CA79  
Air Filter  
Pre-Cleaner  
KOHLER 24 083 02  
KOHLER 24 050 10  
Fuel Filter  
Spark Plugs  
(Resistor  
Type)  
CHAMPIONꢀRC12YC  
(.030” GAP)  
* Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-1  
E-1  
TROUbLESHOOTING  
HOW TO USE TROUbLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and  
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical  
Shock, please observe all safety notes and precautions detailed throughout this manual.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEMꢀ(SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-2  
E-2  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
No welder output power or Auxiliary 1. Open in miscellaneous leads.  
Power.  
2. Open lead in flashing or field  
circuit.  
3. Faulty rotor.  
4. Faulty Potentiometer (R1).  
5. Faulty stator Field winding.  
6. Faulty Field rectifier (On PCB*).  
7. Faulty P.C. Board.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
Engine will not idle down to low  
speed.  
1. Idler switch on High Idle.  
2. Insufficient voltage present on  
idler solenoid terminals.  
(Voltage should be 12V to 14V  
DC).  
3. External load on welder or  
auxiliary power.  
4. Faulty wiring in solenoid circuit.  
5. Faulty idler solenoid.  
6. Faulty P.C. Board.  
Engine will not go to high idle when 1. Poor work lead connection to  
attempting to weld.  
work.  
2. No voltage signal from the  
current sensor.  
3. No open circuit voltage on  
output studs.  
4. Faulty P.C. Board.  
* Printed Circuit Board (PCB)  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-3  
E-3  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
Engine will not go to high idle when 1. No voltage signal from the  
using auxiliary power.  
current sensor.  
2. Auxiliary power load less than  
100 to 150 watts.  
3. Faulty P.C. Board.  
Engine will not crank or is hard to  
crank.  
1. Battery will not hold a charge.  
Faulty Battery.  
2. No or insufficient charging  
current.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
3. Loose battery cable  
connection(s).  
Engine shuts down.  
1. Out of fuel.  
2. Low oil level.  
Engine does not develop full power. 1. Fuel filter clogged.  
2. Air filter clogged.  
Engine is hard to start.  
1. Spark plugs do not have  
specified gap.  
2. Spark plugs are fouled.  
3. Out of fuel.  
4. Fuel filter clogged.  
5. Electric fuel pump not working.  
6. Mechanical fuel pump not work-  
ing.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-1  
F-1  
DIAGRAMS  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-2  
F-2  
DIAGRAMS  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-3  
F-3  
DIAGRAMS  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-4  
F-4  
DIMENSION PRINT  
RANGER® 250 GXT  
Download from Www.Somanuals.com. All Manuals Search And Download.  
l Do not touch electrically live parts or  
electrode with skin or wet clothing.  
l Insulate yourself from work and  
ground.  
l Keep flammable materials away.  
l Wear eye, ear and body protection.  
WARNING  
Spanish  
l No toque las partes o los electrodos l Mantenga el material combustible  
l Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
l Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
l Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
l Gardez à l’écart de tout matériel  
inflammable.  
l Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
l Isolez-vous du travail et de la terre.  
German  
l Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
l Isolieren Sie sich von den  
l Entfernen Sie brennbarres Material! l Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
l Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
l Mantenha inflamáveis bem guarda- l Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
l Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE  
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS  
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-  
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
l Keep your head out of fumes.  
l Use ventilation or exhaust to  
remove fumes from breathing zone.  
l Turn power off before servicing.  
l Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
l Los humos fuera de la zona de res-  
piración.  
l Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
l Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
l No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
l Débranchez le courant avant l’entre- l N’opérez pas avec les panneaux  
tien.  
l Gardez la tête à l’écart des fumées.  
l Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
l Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
l Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
l Vermeiden Sie das Einatmen von  
Schweibrauch!  
l Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
l Não opere com as tampas removidas.  
l Desligue a corrente antes de fazer  
serviço.  
l Mantenha-se afastado das partes  
moventes.  
l Não opere com os paineis abertos  
ou guardas removidas.  
l Mantenha seu rosto da fumaça.  
l Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
l Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Leica Heat Pump GS20 User Manual
Lennox International Inc Heat Pump 4HP18LT User Manual
Lightolier Indoor Furnishings 1101FDM User Manual
Lowrance electronic GPS Receiver Baja 840C User Manual
Makita Impact Driver 6920NB User Manual
Makita Trimmer EM4340 User Manual
Manitowoc Ice Ice Maker 7626803 User Manual
Marantz Stereo Receiver SR 18EX User Manual
Meade Telescope 60EQ D User Manual
Meade Telescope LX200 R User Manual