Lincoln Electric RANGER 275 manual

Ranger 275 OPERA TOR’S MANUAL IM606 July, 2001 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 AND[...]

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. ________________________________________________[...]

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 skin[...]

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 manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv PRÉCA UTIONS 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 L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits [...]

Thank You for selecting this QUALITY product. We want you to take pride in operating this 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 particular attention to the safety instructio[...]

vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .......................................................................................................A-1 Installation Instructions. .....................[...]

vii T ABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine and Periodic Engine Maintenance .........................................[...]

A-1 INST ALLA TION RANGER 275 A-1 TECHNICAL SPECIFICA TIONS - Rang er 275 K ohler Engine (K1641-1) Make/Model Description Speed (RPM) Displacement Starting Capacities System Kohler 2 cylinder High Idle 3700 38 cu. in(624 cc) 12VDC battery Fuel: 9.0 gal. 20.0 HP @ Low Idle 2400 (Group 58, 435 (34 L) CH20 3600 RPM Full Load 3400 cold crank amps) Full[...]

A-2 INST ALLA TION RANGER 275 A-2 TECHNICAL SPECIFICA TIONS - Rang er 275 (K1641-1)[...]

A-3 INST ALLA TION RANGER 275 A-3 INST ALLA TION INSTR UCTIONS SAFETY PRECA UTIONS Only qualified per sonnel should install, use, or service this equipment. LOCA TION AND VENTILA TION Whenever you use the Ranger 275, be sure that clean cooling air can flow through the machine’s engine and the machine case. Avoid dusty, dirty areas. Also, keep the[...]

A-4 INST ALLA TION RANGER 275 A-4 HIGH AL TITUDE OPERA TION At high altitude, the standard carburetor air-fuel mix- ture will be too rich. Performance will decrease, and fuel consumption will increase. A very rich mixture will also foul the spark plug and cause hard starting. High altitude performance can be improved by specific modifications to th[...]

A-5 INST ALLA TION RANGER 275 A-5 FUEL Fill the fuel tank with clean, fresh regular grade lead- free gasoline. Observe the fuel gauge while filling to prevent overfilling. The Ranger 275 has a 9 U.S. gallon (7.5 Imp. Gal., 34L) fuel tank mounted below the generator. See the Engine Owners Manual for more details about the fuel. B A TTER Y CONNECTION[...]

A-6 INST ALLA TION RANGER 275 A-6 ELECTRICAL CONNECTIONS See Figure B.1 in the OPERATION section of this manual for location of the 120 and 240 volt recepta- cles, weld output terminals, circuit breakers and ground stud. MA CHINE GROUNDING Because the Ranger 275 creates its own power from its engine driven generator, and if the machine is not conne[...]

A-7 INST ALLA TION RANGER 275 A-7 A UXILIAR Y PO WER RECEPT A CLES, PLUGS, AND HAND-HELD EQUIPMENT The control panel of the Ranger 275 features three auxiliary power receptacles: See Figure B.1. • Two 15 amp, 120 volt duplex (double outlet) recepta- cles. • One 50 amp 120/240 volt single outlet receptacle. Through these receptacles the machine [...]

A-8 INST ALLA TION RANGER 275 A-8 Connection of Ranger 275 to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes. 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 OVER[...]

B-1 OPERA TION RANGER 275 B-1 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your Ranger 275. SAFETY INSTR UCTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man- uals supplied with your machine. They include impor- tant safety precautions, detailed engine st[...]

B-2 OPERA TION B-2 RANGER 275 • One 50 amp 120 V single phase AC dual voltage power receptacle with two 50 amp circuit breakers. Supplies up to 38 amps of 240 V AC and up to 76 amps of 120 V AC single phase auxiliary power per side to separate branch circuits (not in parallel). Allows easy connection to premises wiring. • Welding and AC auxilia[...]

B-3 OPERA TION B-3 RANGER 275 CONTR OLS AND SETTINGS All generator/welder controls are located on the Output Control Panel of the machine case front. Idler control, and start/stop controls are also on the case front. See Figure B.1 and the explanations that follow. FIGURE B.1 OUTPUT P ANEL CONTROLS WELDER/GENERA T OR CONTROLS See Figure B.1 for the[...]

B-4 OPERA TION B-4 RANGER 275 ENGINE OPERA TION DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS. The maximum allowable high idle speed for the Ranger 275 is 3750 RPM, no load. Do NOT adjust the governor screw on the engine. Severe per- sonal injury and damage to the machine can result if it is operated at speeds above the maximum rated speed. -----------[...]

B-5 OPERA TION B-5 ST OPPING THE ENGINE Remove all welding and auxiliary power loads and allow the engine to run at low idle speed for a few minutes to cool the engine. Stop the engine by placing the “Engine” switch in the “STOP” position. A fuel shut off valve is not required on the Ranger 275 because the fuel tank is mounted below the eng[...]

B-6 OPERA TION B-6 “ ARC CONTROL ” The “ARC CONTROL” is active in two modes: “STICK/TIG” and “WIRE WELDING” and has different purposes in each mode. It is not active in the “PIPE” mode. “ STICK/TIG ” mode: In this mode, the “ARC CON- TROL” knob sets the short circuit (arc force) current during stick welding. Increasing t[...]

B-7 OPERA TION B-7 When the triggering device is pressed the contactor is closed and the welding terminals are “Hot.” When the triggering device is released the contactor is opened and the welding terminals are “Cold.” “ MODE ” Switch - Set to the desired process: STICK/TIG, PIPE, or WIRE FEED. “ WIRE FEEDER V OL TMETER ” Switch - I[...]

B-8 OPERA TION B-8 RANGER 275 Tungsten Electrode Diameter in. (mm) 2-15 5-20 15-80 70-150 150-250 250-400 400-500 500-750 750-1000 (3) (3) (3) 10-20 15-30 25-40 40-55 55-80 80-125 3-8 (2-4) 5-10 (3-5) 5-10 (3-5) 9-13 (4-6) 11-15 (5-7) 11-15 (5-7) 13-17 (6-8) 18-22 (8-10) 23-27 (11-13) TIG TORCH Nozzle Size (4), (5) Approximate Argon Gas Flow Rate C[...]

B-9 OPERA TION B-9 RANGER 275 T ABLE B.3 SUMMAR Y OF WELDING PROCESSES AND MA CHINE SETTINGS CONTROL CABLE USED MODE SWITCH IDLER SWITCH OUTPUT CONTROL SWITCH CONTACTOR SWITCH ELECTRODE WHEN NOT WELDING TO START WELDING PROCESS STICK - CC TIG - CC K930-1 TIG MODULE / K936-1 CONTROL CABLE (With Amptrol) WIRE FEED - CV, LN-25 WITH 42V REMOTE CON- TRO[...]

B-10 OPERA TION B-10 RANGER 275 A UXILIAR Y PO WER Start the engine and set the "IDLER" control switch to the desired operating mode. Full power is available regardless of the welding output settings, if no welding current is being drawn. The auxiliary power of the Ranger 275 consists of two 15 Amp-120VAC (5-15R) duplex receptacles and on[...]

C-1 A CCESSORIES C-1 GENERAL OPTIONS / A CCESSORIES The following options/accessories are available for your Ranger 275: K886-1 Canvas Cover - To protect the Ranger 275 when it is not being operated. Made from attractive red canvas material that is flame retardant, mildew resistant and water repellent. K889-2 Two Wheel Undercarriage - For moving by[...]

C-2 A CCESSORIES C-2 SEMIA UT OMA TIC FCA W AND MIG WELDING OPTIONS / A CCESSORIES LN-25 Wire Feeder - This portable unit can be used for flux-cored arc welding (FCAW) and metal inert gas welding (MIG). LN-7 Wire Feeder - Semiautomatic constant speed wire feeder. NOTE : Gas-shielded welding requires a Magnum Gun. Gasless welding requires an Innersh[...]

C-3 C-3 RANGER 275 A CCESSORIES - CONNECTION DIA GRAMS 6 PIN AMPHENOL TO WORK 14 PIN AMPHENOL LN-25 N.E. PLACE THE WELDING TERMINALS SWITCH IN THE "ALWAYS ON" POSITION. N.C. PLACE THE MODE SWITCH IN THE "WIRE WELDING-CV" POSITION. N.F. PLACE IDLER SWITCH IN "AUTO" OR "HIGH" IDLE POSITION AS DESIRED. S24095-1 [...]

C-4 C-4 RANGER 275 A CCESSORIES - CONNECTION DIA GRAMS 14 PIN TO WORK AMPHENOL WARNING Keep guards in place. or service this equipment. Keep away from moving parts. Only qualified personnel should install,use CONTROL MODULE CONNECTION DIAGRAM Do not touch electrically live parts. ELECTRODE TO WORK CABLE PLUG CAUTION : DAMAGED. THE ENGINE GOVERNOR S[...]

C-5 C-5 RANGER 275 A CCESSORIES - CONNECTION DIA GRAMS CAUTION : or service this equipment. Keep away from moving parts. Keep guards in place. ELECTRODE TO WORK TO WORK CABLE PLUG K592 CONTROL CABLE TO LN-742 INPUT TO WIRE FEED UNIT ELECTRODE CABLE AMPHENOL 14 PIN N.D. PLACE WELDER TERMINALS SWITCH TO "REMOTELY CONTROLLED" POSITION. N.C. [...]

C-6 C-6 RANGER 275 A CCESSORIES - CONNECTION DIA GRAMS Keep away from moving parts. 31 NOT USED ON RANGER POWER SOURCES 42 TO WIRE FEED UNIT ELECTRODE CABLE ADAPTER PLUG K867 UNIVERSAL Only qualified personnel should install,use 82 41 81 Do not touch electrically live parts. 4 2 SPARE CAUTION : RANGER 275 TO K867 CONTROL CABLE ADAPTER CONNECTION DI[...]

C-7 C-7 RANGER 275 A CCESSORIES - CONNECTION DIA GRAMS A S24095-9 ELECTRODE DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE ANY INCREASE OF THE HIGH IDLE ENGINE RPM B[...]

D-1 MAINTENANCE D-1 R OUTINE AND PERIODIC ENGINE MAINTENANCE At the end of each day’s use, refill the fuel tank to min- imize 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. ENGINE MAINTENANCE P ARTS T ABLE D .1 * Oil capicity increases f[...]

D-2 MAINTENANCE D-2 RANGER 275 T ABLE D .2 K OHLER ENGINE MAINTENANCE SCHEDULE Regular Service Period (3) Each Use 5 Hrs. 25 Hrs. Every 100 Hrs. Every 200 Hours ITEM Perform at every indicated month or operating hour interval, whichever comes first. Engine Oil (1) Check Level O Change First Oil Change O Engine Oil Filter (1) Replace O Air Pre Clean[...]

D-3 MAINTENANCE D-3 CHANGING THE ENGINE OIL Drain the oil while the engine is warm to assure rapid and complete draining. 1. Remove the oil filler cap and drain cap, and drain the oil into a suitable container. 2. Retighten the drain cap securely. 3. Refill to the upper limit mark on the dipstick with the recommended oil. Tighten the oil filler cap[...]

D-4 MAINTENANCE D-4 KOHLER ENGINE Air Precleaner Service 1. Loosen the cover retaining knob and remove the cover. 2. Remove the precleaner from the paper element. 3. Wash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precl[...]

D-5 MAINTENANCE D-5 FUEL FIL TER SER VICE 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 ADJUSTMENTS OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM, no load. Do NOT tamper with governor component[...]

D-6 MAINTENANCE D-6 After cleaning, flush the outside of the battery, the bat- tery compartment, and surrounding areas with clear water. Coat the battery terminals lightly with petrole- um jelly or a non-conductive grease to retard corro- sion. Keep the battery clean and dry. Moisture accumula- tion on the battery can lead to more rapid discharge a[...]

E-1 TR OUBLESHOO TING E-1 RANGER 275 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. CA UTION This Troubleshooting Guide is provided to help you locate and repair po[...]

RANGER 275 E-2 TR OUBLESHOO TING E-2 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. CA UTION PROBLEMS [...]

RANGER 275 E-3 TR OUBLESHOO TING E-3 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. CA UTION PROBLEMS [...]

RANGER 275 E-4 TR OUBLESHOO TING E-4 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. CA UTION PROBLEMS [...]

F-1 DIA GRAMS F-1 RANGER 275 WIRING DIAGRAM WHITE 115/230V 6E 3E TERM. J10 J12 J11 115AC CONTACTOR WORK REMOTE CONTROL 42VAC GROUND J A D C H E F G I K B NEG. CHOKE PCB3 L1 5B 6B 5E CONTROL SHOWN IN CB6 CB5 CB2 CB1 1 3 4 6 IDLER CONTROL "AUTO" POSITION 218 220 S5 SHOWN IN CB3 50K 3 4 6 1 6 3 4 6 CAP CAP PCB1 PCB2 IN DIRECTION SHOWN WRAP 2[...]

F-2 DIA GRAMS F-2 RANGER 275 21.21 CENTER OF GRAVITY WITH OIL IN ENGINE AND FUEL TANK EMPTY. 9.31 9.29 17.00 13.30 8.80 9.09 26.59 30.28 42.00 UNDERCARRIAGE MOUNTING HOLES 9.09 9.09 18.17 OF SHAFT L C 23.00 30.00 DIMENSION PRINT A M19147-2[...]

NO TES RANGER 275[...]

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W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O 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 [...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES 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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