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Lincoln Electric 275 Welder User Manual

1. 1 ACCESSORIES C 1 GENERAL OPTIONS ACCESSORIES 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 hand Two 4 00 x 8 pneumatic tires Overall width 29 74m K893 1 Caster for K889 2 Undercarriage Mounts to the front of the Two Wheel undercarriage to allow easy movement on smooth surfaces Includes a 6 diameter hard rubber wheel with a convenient toe on toe off locking brake K933 1 Four Wheel Undercarriage Allows move ment of the Ranger 275 by hand without lifting on smooth surfaces Includes two rugged hard molded wheels and two durable pneumatic tires The spring loaded handle provides convenient comfortable steer ing The K934 1 Bracket is available for mounting a gas cylinder on the undercarriage K934 1 Bracket for Mounting a Gas Cylinder to a K933 1 Undercarriage Easily mounts on the back of the K933 1 Four Wheel Undercarriage to carry a weld ing gas cylinder K957 1 Two Wheeled Trailer For in plant or yard towing of the Ranger 275 Suitable for road towing with optional Fender and Light Kit The following options are available for the K957 1 Two Wheeled Trailer K958 1 Ball Coupler 2 K958 2 Lunette Eye Coupler K959 2 Fender amp Light K96
2. 3 Remove clean out plug on bottom of spark arrestor 4 Lightly tap on arrestor around drain hole to remove particulate 5 t may be necessary to poke around inside drain hole with a wire or screwdriver to break up particu late 6 Reinstall clean out plug WELDER GENERATOR MAINTENANCE STORAGE Store the Ranger 275 in clean dry protected areas CLEANING Blow out the generator and controls periodically with low pressure air Do this at least once a week in par ticularly dirty areas BRUSH REMOVAL AND REPLACEMENT It is normal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator overhaul is necessary WARNING Do not attempt to polish slip rings while the engine is running RANGER 275 LINCOLN 8 E 1 TROUBLESHOOTING E 1 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 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLE
3. After the engine has started slowly return the choke control to the full in position choke open In the AUTO position the engine will run at high idle for 10 14 seconds and then go to low idle Allow the engine to warm up by letting it run at low idle for a few minutes At cold temperatures it may be necessary to start the engine in HIGH idle and allow it to run for several minutes before using AUTO idle When starting a hot engine it is not necessary to pull the choke out but the engine will start faster if it is pulled out Push it in immediately after the engine starts CAUTION Operating the starter motor for more than 5 seconds can damage the motor If the engine fails to start release the switch and wait 10 seconds before operat ing the starter again Do not push the Start button while the engine is running because this can damage the ring gear and or starter motor NOTE When starting a Ranger 275 for the first time after an extended period of not operating it will take longer than normal because the fuel pump has to fill the fuel line and carburetor RANGER 275 LINCOLN P B 5 OPERATION B 5 STOPPING THE ENGINE Stop the engine by placing the Engine switch in the STOP position 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 A fuel shut off valve is not required on the Ranger 275 because the fuel tank
4. MODE SWITCH IDLER SWITCH CONTROL SWITCH STICK TIG AUTO LOCAL or PIPE STICK TIG AUTO REMOTE WIRE FEED AUTO REMOTE WIRE FEED AUTO LOCAL WIRE FEED AUTO REMOTE WIRE FEED HIGH REMOTE RANGER 275 LINCOLN P SWITCH WELDING ON CONTACTOR CONTROLLED CONTACTOR CONTROLLED WELDING ON CONTACTOR CONTROLLED CONTACTOR CONTROLLED OUTPUT CONTACTOR ELECTRODE WHEN NOT WELDING HOT TO START WELDING Touch electrode to work Welding starts immediately and engine goes to high idle Press Amptrol Ranger 275 contactor closes Welding starts immediately and engine goes to high idle Press gun trigger Ranger 275 contactor closes Welding starts immediately and engine goes to high idle Press gun trigger LN 25 contactor closes Welding starts immediately and engine goes to high idle Press gun trigger Ranger 275 contactor closes Welding starts immediately and engine goes to high idle Press gun trigger Ranger 275 contactor closes Welding starts immediately B 10 AUXILIARY POWER 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 one 50 Amp 120 240 VAC 14 50R receptacle The auxiliary power capacity is 9 000 watts of 60 Hz single phase p
5. WARNING ELECTRIC SHOCK can kill Do notoperate with panels open Disconnect NEGATIVE BATTERY LEAD before servicing Do not touch electrically live parts 14 PIN AMPHENOL 81 MOVING PARTS can injure Keep guards in place Keep away from moving parts Only qualified personnel should install use or service this equipment fU 82 NOT USED ON RANGER POWER SOURCES SPARE O K867 UNIVERSAL 2 CONNECT TOGETHER FOR ADAPTER PLUG 4 h O 41 o 42 O 31 O 32 O 115 VAC TO WORK ELECTRODE 42 VAC WELDING OUTPUT GND O POWER SOURCE FRAME CONNECTION 21 O WIRE FEEDER VOLTMETER CONNECTION ELECTRODE CABLE CONNECTS TO WORK TERMINAL OF POWER SOURCE pni TO WIRE FEED UNIT 77 aoe 76 V y TO WORK EN oT MIN CAUTION REMOTE OUTPUT CONTROL ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION N B CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER
6. use demands LIMITATIONS The Ranger 275 is not recommended for any processes besides those that are normally per formed using stick welding SMAW TIG welding GTAW MIG GMAW welding and Innershield FCAW welding The Ranger 275 is not recommended for pipe thawing During welding generator power is limited and out put voltages can drop Therefore DO NOT OPER ATE ANY SENSITIVE ELECTRICAL EQUIPMENT WHILE YOU ARE WELDING See Table B 4 for permissible simultaneous welding and auxiliary power loads 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 Only qualified personnel should install use or service this equipment RANGER 275 LINCOLN P B 3 CONTROLS AND SETTINGS All generator welder controls are located on the Output Control Panel of the machine case front Idler OPERATION B 3 put contactor With the switch in the CONTACTOR ON position the contactor is closed at low and high idle 6 BATTERY CHARGER CIRCUIT BREAKER Opens control and
7. EXPLOSION when e INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new battery last e CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting nega tive cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated e USING A BOOSTER connect positive lead to battery first then connect negative lead to negative battery lead at engine foot e Wear gloves and eye protection and d be careful when working near battery e Follow instructions printed on battery BATTERY ACID can burn eyes and skin To prevent ELECTRICAL DAMAGE when a Installing a battery b Using a booster Use correct polarity Negative Ground To prevent BATTERY DISCHARGE if you have an ignition switch turn it off when engine is not running The battery is a group 58 with a rating of 435 cold cranking amps CLEANING THE BATTERY Keep the battery clean by wiping it with a damp cloth when dirty If the terminals appear corroded discon nect the battery cables and wash the terminals with an ammonia solution or a solution of 1 4 pound 0 1113 kg of baking soda and 1 quart 0 946 L of water Be sure the battery vent plugs if equipped are tight so that none of the solution enters the cells RANGER 275 LINCOLN 8 D 6 MAINTENANCE D 6 After cleaning flush the outside of the battery the bat tery compartment and
8. HAND AMPTROL 14 PIN OR AMPHENOL K814 ARC START SWITCH ELECTRODE CAUTION ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N B CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY N C PLACE THE MODE SWITCH IN THE STICK WELD POSITION N D PLACE WELDER TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION N E PLACE OUTPUT CONTROL SWITCH IN REMOTE CONTROL POSITION N F PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 524095 9 275 LINCOLN 8 D 1 MAINTENANCE pa SAFETY PRECAUTIONS ROUTINE AND PERIODIC ENGINE A WARNING MAINTENANCE Have qualified personnel do the maintenance At the end of each day s use refill the fuel tank to min work Turn the engine off before working inside imize moisture condensation in the tank Running out ihe macnine In some cases it may be of fuel tends to draw dirt into the fuel system Also necessary to remove safety guards to perform check the crankcase oil level a
9. Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed RANGER 275 LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION Major Physical or Electrical Damage 1 Contact your Local Lincoln Authorized is Evident Field Service Facility Engine will not crank 1 Battery is low 1 Charge Battery Loose battery cable connections 2 Inspect clean and tighten Faulty engine starter motor 3 Contact authorized engine Service Shop Battery Circuit circuit breaker is 4 Re set If it continues to trip contact tripped your local Local Lincoln Authorized Field Service Facility Engine will crank but not start Out of fuel 1 Fill tank and start engine Engine switch in OFF position 2 Set switch to ON position Faulty fuel solenoid or faulty PC 3 Contact your Local Lincoln Authorized board or ignition system Field Service Facility or authorized engine service shop Engine shuts down shortly after 1 Low oil level 1 Change oil and oil filter and fill to prop er level Start engine and look for leaks Faulty oil pressure switch or other 2 Contact your Local Lincoln Authorized engine component Field Service Facility or authorized engine service shop Open rotor circuit 3 Contact your Local Lincoln Authorized Field Service Facil
10. Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese 5 BIR Korean Donot touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Notoque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pieces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden N o toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra ORBPOBARA iAH J T 19697 pri ATUBS ELTFEL e E eski An 945 e ft B SUE HER ecran 2452 Xe FE Bp HZA e 2x9 HIE Weal Ju Gu gone uil oh puni das 1 SONT gh uae pally apad Jai DA dua Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos THEN A e i 9 5 Vi B T IF PF o 12 AS AIX
11. Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 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 6 h Also see item 1 c LINCOLN 8 CYLINDER may explode 22 s if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from ar
12. battery from welder by disconnecting nega tive cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING A BOOSTER connect positive lead to battery first then connect negative lead to negative battery lead at engine foot gt BATTERY ACID can burn eyes and skin e Wear gloves and eye protection and be careful when working near battery e Follow instructions printed on battery IMPORTANT To prevent ELECTRICAL DAMAGE WHEN a Installing new batteries b Using a booster Use correct polarity Negative Ground The Ranger 275 is shipped with the negative battery cable disconnected Before you operate the machine make sure the Engine Switch is in the STOP position and attach the disconnected cable securely to the negative battery terminal Remove the insulating cap from the negative battery terminal Replace and tighten negative battery cable terminal NOTE This machine is furnished with a wet charged battery if unused for several months the bat tery may require a booster charge Be sure to use the correct polarity when charging the battery MUFFLER A CAUTION Shut off the machine and allow the muffler to cool before touching the muffler The Ranger 275 is shipped with the exhaust coming out on the left side The exhaust can be changed to the opposite side by removing the two screws that hold the exhaust port cover in place and install
13. cables to your Ranger 275 as fol lows See Figure B 1 for location of parts 1 The engine must be OFF to install welding cables 2 Remove the flanged nuts from the output terminals 3 Connect the electrode holder and work cables to the weld and output terminals The terminals are identified on the case front The polarity require ment for the welding process being used deter mines which terminal the electrode cable is attached to 4 Tighten the flanged nuts securely 5 Be certain that the metal piece you are welding the work is properly connected to the work clamp and cable 6 Check and tighten the connections periodically CAUTION Loose connections will cause the output terminals to overheat The terminals may eventually melt Do not cross the welding cables at the output termi nal connection Keep the cables isolated and sepa rate from one another RANGER 275 LINCOLN 8 7 INSTALLATION A 7 AUXILIARY POWER RECEPTACLES 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 can supply up to 9 000 rated continuous watts of single phase 60 Hz AC power For further protection against electric shock any elec trical equipment connected to the 120V
14. constant current weld ing power sources having an internal contactor The TIG Module is supplied without accessories Arc Start Switches Amptrols cables torches and mounting brackets must be purchased separately K939 1 Docking Kit For mounting the K930 1 TIG Module on top of the Ranger 275 K936 1 Control Cable Control cable for connecting the K930 2 TIG Module to a Ranger 275 K814 Arc Start Switch A remote start switch used in conjunction with the K930 2 TIG Module to energize the Ranger 275 output terminals via the TIG module K963 Hand Amptrol Remote output control and contactor control K870 Foot Amptrol Remote output control and con tactor control RANGER 275 LINCOLN 8 C 2 ACCESSORIES SEMIAUTOMATIC FCAW AND MIG WELDING OPTIONS ACCESSORIES 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 Innershield Gun K487 25 Magnum Spool Gun A lightweight semi automatic wire feeder for aluminum welding with argon gas Has built in remote wire speed control in the handle Requires the K488 SG Control Module Includes 25 feet 7 6 meters of power cable K488 SG Control Module Controls wire speed and gas flow Provides the required control interface between the Ranger 275 and the K487 25 Magnu
15. electrician and must comply with the National Electrical Code and all other applicable electrical codes RANGER 275 LINCOLN 8 1 OPERATION B 1 OPERATING INSTRUCTIONS Read and understand this entire section before oper ating your Ranger 275 SAFETY INSTRUCTIONS WARNING 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 starting operating and maintenance instructions and parts lists e ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring elnsulate yourself from the work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 23 XN Do not stack anything near the engine 20 MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts Only qualified personnel should operate this equip ment GENERAL DESCRIPTION The Ranger 275 is an engine driven multi process DC arc welder and AC power generator for commer cial and residential applications As a generator it can supply up to 9 000 continuous watts of 120 240 volt 60 Hz single phase AC power to operate AC power tools battery chargers and lighting it can also be used to provide st
16. injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts WELDING SPARKS can cause fire or Mo explosion Keep flammable material away ARC RAYS can burn 4 Wear eye ear and body protection 5 1 See additional warning information throughout this operator s manual WELDER CONTROLS FUNCTION AND OPERATION See Figure B 1 for control locations Output CONTROL Continuous CC welding current control from 20 amps to 300 amps in the STICK TIG and PIPE modes Continuous CV welding arc voltage control from 11 volts to 32 volts in the WIRE FEED mode 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 CON TROL knob sets the short circuit arc force current during stick welding Increasing the number from 1 to 10 increases the short circuit current This prevents sticking of the electrode to the plate at low welding current settings This also increases spatter It is rec ommended that the control is set to the minimum number without electrode sticking WIRE WELDING mode In this mode increasing the number from 1 to 10 changes the arc from soft and washed in to crisp and narrow It acts as an inductance control The proper setting depends on the application and operator prefere
17. moventes N o opere com os paineis abertos ou guardas removidas e V J P p 7 t pk L Z CRMBIEE U uA CG F uv e 838 1811 Bd BUS 8 e Ro egado Yel HAE AHSA AREY cds 13 Jal lla Gada ve WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENCAO Japanese it ies BR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR f 5 81 Pis 0 0 k lt BMA ECL TCHHORERME I Rr de fit D RES fE FE B BUR BS SEE ZHAXIAINE nie SAISIR FA HAURA CHAS ETAT sp Saal cual 91 alayla aui J al gll Gail guet agil g cas LINCOLN 5 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 WEB SITE www lincolnelectric com
18. ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie do LES MACHINES SOUDER Un c
19. 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 and early battery failure CHECKING ELECTROLYTE LEVEL If battery cells are low fill them to the neck of the filler hole with distilled water and recharge If one cell is low check for leaks CHARGING THE BATTERY When you charge jump replace or otherwise con nect battery cables to the battery be sure the polarity is correct Improper polarity can damage the charging circuit The Ranger 275 positive battery terminal has a red terminal cover If you need to charge the battery with an external charger disconnect the negative cable first then the positive cable before you attach the charger leads after the battery is charged reconnect the positive battery cable first and the negative cable last Failure to do co can result in damage to the internal charger components Follow the instructions of the battery charger manu facturer for proper charger settings and charging time SERVICING OPTIONAL SPARK ARRESTOR A WARNING MUFFLER MAY BE HOT e ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTOR U DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTOR Service every 100 hours 2 Shut off engine and allow muffler to cool
20. to check the oil regularly and keep the oil level at the FULL mark as it would be in its normal level condition Also fuel capacity will be a little less at an angle RANGER 275 LINCOLN 8 A 4 HIGH ALTITUDE OPERATION 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 the carburetor If you always operate your engine at altitudes above 6 000 feet 1 800 meters have a engine dealer perform this carburetor modification Even with carburetor modification engine horsepower will decrease about 3 596 for each 1 000 feet 300 meter increase in altitude The effect of altitude on horsepower will be greater than this if no carburetor modification is made Do not operate a modified engine below 6 000 feet LIFTING The Ranger 275 weighs approximately 469 165 212 kg A lift bail is mounted to the machine frame and should always be used when lifting the machine ADDITIONAL SAFETY PRECAUTIONS A WARNING WE FALLING EQUIPMENT can cause injury e Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder e Lift only with equipment of adequate lifting capacity e Be sure machine is stable when lifting INSTALLATION 4 PRE OPER
21. uie a Jo ALD a gll pis Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use para a vista ouvido e corpo e BH HRUBS ISUCRSREUCT GAA RRR ez 12 59 s ESSA 4 Lily ranas cl ysl n e danny 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 UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour
22. ventilated to an open outside area The Ranger 275 may be used outdoors Do not set the machine in puddles or otherwise submerge it in water Such practices pose safety hazards and cause improper operation and corrosion of parts INSTALLATION A 3 Always operate the Ranger 275 with the case roof on and all machine components completely assembled This will protect you from the dangers of moving parts hot metal surfaces and live electrical devices STORING 1 Store the machine in a cool dry place when it is not in use Protect it from dust and dirt Keep it where it can t be accidentally damaged from con struction activities moving vehicles and other hazards 2 Drain the engine oil and refill with fresh oil Run the engine for about five minutes to circulate oil to all the parts See the MAINTENANCE section of this manual for details on changing oil 3 Remove the battery recharge it and adjust the electrolyte level Store the battery in a dry dark place STACKING Ranger 275 machines CANNOT be stacked ANGLE OF OPERATION Place the machine on a secure level surface whenev er you use it or store it Any surfaces you place it on other than the ground must be firm non skid and structurally sound The engine is designed to run in a level position for best performance It can operate at an angle but this should never be more than 15 degrees in any direc tion If you do operate it at a slight angle be sure
23. 20 V AC duplex receptacles for up to 60 amps of 120 VAC power RANGER 275 LINCOLN 8 B 2 OPERATION B 2 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 auxiliary power at the same time within machine total capacity OTHER FEATURES Overhead valve V twin 20 HP gasoline engine Designed for long life easy maintenance and excel lent fuel economy Engine protection system shuts the engine down with low oil pressure Large maintenance free battery Group 58 with 435 cold cranking amps Battery charging ammeter Engine hour meter Extended range 9 U S gallon 7 5 Imp Gal 34 liters fuel tank Automatic idler reduces engine speed when not welding or drawing auxiliary power This feature reduces fuel consumption and extends engine life Compact size fits crosswise in compact size pick up truck Copper alternator windings for dependability and long life CSA approved RECOMMENDED APPLICATIONS WELDER The Ranger 275 provides excellent constant current DC welding output for stick SMAW welding and for TIG welding and it offers constant voltage output for DC semiautomatic wire feed welding GENERATOR The Ranger 275 gives AC power output for medium
24. 5 1 Cable Rack K894 1 Spark Arrester Kit A field installed kit for the Ranger 275 engine muffler exhaust pipe Includes a heavy gauge steel approved spark arrester mount ing clamp and adapter K703 Accessory Kit Includes the following Thirty five feet 10 5 meters of 1 0 AWG elec trode cable Thirty feet 9 1 meters of 1 0 AWG work cable Headshield with No 12 filter GC500 work clamp Cooltong 300 insulated electrode holder K802 R Power Plug Kit Provides four 15 amp 120 volt plugs and one 50 amp dual voltage 120 240V full kVA plug K857 Remote Control Includes a control box with 25 feet 7 5 meters of 4 conductor cable Allows out put voltage to be controlled remotely K857 1 Remote Control Includes a control box with 100 feet 30 5 meters of 4 conductor cable Allows output voltage to be controlled remotely K896 1 GFCI Receptacle Kit Includes two UL approved 120 volt ground fault circuit interrupter receptacles duplex type with covers and installation instructions Each receptacle is rated 15 amps but the maximum total current from each GFCI duplex is limited to 20 amps The GFCI receptacles replace the two factory installed 120 volt duplex receptacles TIG WELDING OPTIONS ACCESSORIES K930 2 TIG Module The TIG Module is an accesso ry that provides high frequency and shielding gas con trol for AC and DC GTAW TIG welding applications It provides contactor control of
25. ARNING ELECTRIC SHOCK can kill ma MOVING PARTS can injure Do not operate with panels open Disconnect NEGATIVE BATTERY LEAD before servicing Keep guards in place Keep away from moving parts Only qualified personnel should install use Do not touch electrically live parts or service this equipment TO LN 8 INPUT CABLE PLUG K595 CONTROL CABLE 14 PIN AMPHENOL TO WORK ELECTRODE CABLE TO WIRE FEED UNIT CAUTION ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE PLACE THE MODE SWITCH IN THE WIRE WELDING CV POSITION PLACE LOCAL REMOTE SWITCH IN REMOTE POSITION PLACE IDLER SWITCH IN HIGH POSITION 524095 6 RANGER 275 LINCOLN C 6 ACCESSORIES CONNECTION DIAGRAMS C 6 RANGER 275 TO K867 CONTROL CABLE ADAPTER CONNECTION DIAGRAM
26. ATION ENGINE SERVICE CAUTION READ and UNDERSTAND the engine operating and maintenance instructions supplied with this machine A WARNING Keep hands way from the engine muffler or HOT engine parts Stop the engine when fueling Do not smoke when fueling Do not overfill the fuel tank Wipe up spilled fuel and allow the fumes to clear before starting the engine Keep sparks and flame away from the fuel tank 47 The Ranger 275 is shipped with the engine filled with SAE 10W 30 oil CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE If it is not full add enough oil to fill it to the full mark For more information on oil viscosity and service con ditions see the MAINTENANCE section of this manu al and the engine Operators Manual RANGER 275 LINCOLN A 5 INSTALLATION A 5 FUEL m 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 BATTERY CONNECTIONS WARNING gt GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new battery last e CONNECTING A BATTERY CHARGER remove
27. DE Switch Set to the desired process STICK TIG PIPE or WIRE FEED WIRE FEEDER VOLTMETER Switch If using a wire feeder that has a voltmeter set this Switch to match the polarity of the electrode STICK WELDING The Ranger 275 can be used with a broad range of DC stick electrodes The output CONTROL adjusts the full range of 20 to 300 amps Set the ARC CON TROL to low setting to minimize spatter If sticking is a problem turn this control to a higher setting clock wise This will increase the short circuit current arc force PIPE WELDING The PIPE WELDING mode is recommended for manual vertical down techniques on pipe joints using EXX10 type electrodes This slope controlled setting allows the operator to control the welding current by changing the arc length The ARC CONTROL arc force is automatically switched off in this mode TIG WELDING The Ranger 275 can be used in a wide variety of DC Tungsten Inert Gas TIG welding applications When used with the K930 1 or 2 TIG module ratings are limited to 275A at a 6096 duty cycle and 250A at a 80 duty cycle Ranger 275 settings when using the K930 1 or 2 Tig Module a Set the MODE Switch to the STICK TIG setting b Set the IDLER Switch to the AUTO position c Set the LOCAL REMOTE switch to the REMOTE position d Set the WELDING TERMINALS switch to the WELDING TERMINALS REMOTELY CON TROLLED position
28. HE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL WELDING CABLES MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY PLACE THE MODE SWITCH IN THE WIRE WELDING CV POSITION PLACE WELDING TERMINALS SWITCH TO CONTROLLED POSITION REMOTELY IF OPTIONAL K857 REMOTE OUTPUT CONTROL IS CONNECTED TO 6 PIN RECEPTACLE PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITION PLACE IDLER SWITCH IN HIGH IDLE POSITION RANGER 275 LINCOLN 5 524095 8 C 7 ACCESSORIES CONNECTION DIAGRAMS C 7 RANGER 275 K930 TIG MODULE CONNECTION DIAGRAM WARNING ELECTRIC SHOCK can kill ma MOVING PARTS can injure Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving parts before servicing AS Only qualified personnel should install use Do not touch electrically live parts or service this equipment S K930 REGULATOR TIG MODULE FLOWMETER ARGON GAS TO GAS CYLINDER INPUT RANGER FITTING K936 1 d K870 FOOT AMPTROL CONTROL CABLE JR TO WORK DNE K963 1
29. Low Idle 2400 Group 58 435 34 L 3600 RPM Full Load 3400 cold crank amps Full Load Bore x Stroke 3 03 x 2 64 25 A Alternator 77 mm x 67 mm Oil 2 0 Qts 1 9L RATED OUTPUT WELDER CC Stick TIG Pipe and CV Wire Welding 275 Amps 28 volts 100 300 Amps 25 volts 60 80 volts DC OUTPUT GENERATOR Auxiliary Power 9 000 Watts 60 Hz 120 240 Volts 100 Duty Cycle 115 42 Volt Auxiliary Power for Wire Feeders PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 469 lbs 212 kg 1 Duty cycle is based on a 10 minute period This machine can be loaded to 300 amps for 6 minutes out of every 10 minute period 2 Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within x 1096 at all loads up to rated capacity When welding available auxiliary power will be reduced RANGER 275 LINCOLN 8 A 2 INSTALLATION A 2 TECHNICAL SPECIFICATIONS Ranger 275 K1641 1 Stick TIG CC Mode Min and Max Arc Force 4 Max Output DC Volts 0 50 100 150 200 250 300 350 400 DC Output Current Amps PIPE Mode 80 70 60 50 Max Dutput 40 pe DC Volts 30 20 4 E Min Output L NI 0 50 100 150 200 250 300 350 400 DC Output Current Amps WIRE FEED CV Mode 80 70 60 50 40 Max Output DC Vol
30. M SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Symptoms are grouped into the following categories engine problems function prob lems and output problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJUSTMENT S lists the obvious external possibilities that may con tribute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted with out removing the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION If you have exhausted all of the items in step 2 Contact your Local Lincoln Authorized Field Service Facility Do not touch electrically live parts such as output WARNING ELECTRIC SHOCK can kill terminals or internal wiring ENGINE EXHAUST can kill outside QA Use in open well ventilated areas or vent exhaust MOVING PARTS can injure Do not operate with doors open or guards off x Keep away from moving parts Stop engine before servicing e Remove guards only when necessary and replace when work requiring removal is complete Only qualified personnel should install use or service this equipment CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local
31. RETURN TO MAIN MENU E IM606 Ranger 2 5 m For use with machines having Code Numbers 10543 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 THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful Date of Purchase Serial Number Code Number Model Where Purchased OPERATOR S MANUAL ISO 9001 HESS EX NX Designed and Manufactured Under a Quality Progra to ISO 9001 Requirements CERTIFICATE NUMBER 30273 LINCOLN Copyright 2001 Lincoln Global Inc e 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 WEB SITE www lincolnelectric com SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Die
32. SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE N C PLACE THE MODE SWITCH IN THE WIRE WELDING CV POSITION N D INSULATE EACH UNUSED LEAD INDIVIDUALLY N E FOR WIRE FEEDERS THAT RETURN A SIGNAL FOR WELDING OUTPUT USE ISOLATION RELAY TO CLOSE LEADS 2 amp 4 N F REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT D TO K867 RAW 2 04 4 0J TO WIRE FEEDER 524095 7 RANGER 275 691 10 K488 K487 SPOOL GUN CONNECTION DIAGRAM WARNING ELECTRIC SHOCK can kill m Do not operate with panels open Disconnect NEGATIVE BATTERY LEAD before servicing not touch electrically live parts 115V RECEPTACLE RANGER MOVING PARTS can injure Keep guards in place Keep away from moving parts Only qualified personnel should install use orservice this equipment K488 SG CONTROL MODULE A 14 PIN WIRE FEEDER RECEPTACLE 6 PIN REMOTE RECEPTACLE TO WORK ELECTRODE ELECTRODE CABLE TO CONTROL MODULE TO WORK K487 25 SPOOL GUN i K691 10 INPUT CABLE CAUTION BE SURE THAT CONTROL MODULE MODE SLIDE SWITCH IS IN THE LINCOLN CONTACT CLOSURE POSITION BEFORE ATTEMPTING TO OPERATE CONTROL MODULE INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND OR POWER SOURCE ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING T
33. TIG torch nozzles are typically made from alumina ceramic Special applications may require lava nozzles which are less prone to breakage but cannot withstand high temperatures and high duty cycles WIRE WELDING Connect a wire feeder to the Ranger 275 and set welder controls according to the instructions on the appropriate wire feeder connection diagram The Ranger 275 in the WIRE FEED position permits it to be used with a broad range of flux cored wire Innershield and Outershield electrodes and solid wires for MIG welding gas metal arc welding Welding can be finely tuned using the ARC CON TROL Some recommended Innershield electrodes are NR 311 NS 3M NR 207 NR 203 Ni 1 NR 204 H Recommended Outershield electrodes are 0S 70 05 71 Some recommended solid wires for MIG welding are 035 0 9 mm and 045 1 1 mm L 50 L 56 and Blue Max MIG 308 LS For any electrodes including the above recommenda tions the procedures should be kept within the rating of the machine For additional electrode information see Lincoln publications N 675 GS 100 and GS 210 RANGER 275 LINCOLN P OPERATION TABLE B 3 SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS PROCESS STICK CC TIG CC K930 1 TIG MODULE K936 1 CONTROL CABLE With Amptrol WIRE FEED CV LN 25 WITH 42V REMOTE CON TROL KIT WIRE FEED CV LN 25 WITH INTERNAL CONTACTOR WIRE FEED CV LN 742 WIRE FEED CV LN 7
34. This will keep the Solid State contactor open and provide a cold elec trode until the triggering device Amptrol or Arc Start Switch is pressed e Set the ARC CONTROL to minimum See Table B 2 for Typical Current Ranges for Tungsten Electrodes RANGER 275 LINCOLN P OPERATION Table B 2 TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES Tungsten Electrode p 1 2 Diameter Thoriated Tungsten 1 2 Thoriated Tungsten 2 15 5 20 15 80 70 150 150 250 250 400 400 500 500 750 750 1000 Approximate Argon Gas Flow Rate C F H I min TIG TORCH Nozzle Size 4 5 3 8 5 10 5 10 2 4 3 5 3 5 9 13 4 6 11 15 11 15 5 7 5 7 13 17 18 22 23 27 6 8 8 10 11 13 1 When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shielding gases 2 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 1 Thoriated EWTh 1 296 Thoriated EWTh 2 Though not yet recognized by the AWS Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications 3 DCEP is not commonly used in these sizes 4 TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 in 5 5 16 in 6 3 8 in 7 7 16 in 8 1 2 10 5 8 6 8 10 11 12 5 16 b
35. acturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 LINCOLN 8 SAFETY WELDING SPARKS can gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 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 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 Hecommended Safe Practices for the Preparation for
36. andbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials
37. andby power As a welder it pro vides up to 300 amps of DC current for DC stick weld ing and DC semiautomatic wire feed welding The Ranger 275 can also perform DC TIG welding DESIGN FEATURES FOR WELDING DC constant current output for stick and TIG weld ing Two continuous CC output settings of 20 to 300 amps one for general purpose stick and tig welding and one with a fixed controlled slope for out of position and pipe welding The STICK TIG mode includes an arc force control DC constant voltage output for MIG and Flux Cored wire welding One continuous CV welding range of 11 to 32 volts Excellent MIG welding with CO2 and blended gas A pinch control allows the arc to be fine tuned from soft to crisp The recommended wire feeder is the K446 LN 25 with the K624 1 42 Volt Remote Output Control Module or the K449 LN 25 with an internal contactor 100 duty cycle at 275 amps output Remote control capability Nine pin and fourteen pin connectors for easy connection of Lincoln wire feeders and remote control accessories The 14 pin connector includes power for 42 VAC wire feeders Internal Solid State contactor allows for the selec tion of hot or cold output terminals FOR AUXILIARY POWER 9 000 watts of 240 V AC 60Hz auxiliary power Power for tools 120 240 lights electric pumps and for standby emergency power Power a 5 HP motor provided it is started under no load Two 15 amp industrial grade 1
38. arts D 1 Engine Maintenance Schedule sse D 2 Changing the Engine Oil uuu nne D 3 Changing the Engine Oil Filter ss D 3 Air Cleaner 5 te Per ed eap eere sente les det D 3 Pl giSetvice cocer eio i eo ER POR REOR HERE o aaa D 4 Fuel Eilter SemviCe iot PER he ace ia eti D 5 Engine Adj strrients c cis ie i e i CR CR HR REPE des D 5 Battery Maintenance ierit D 5 Servicing Optional Spark Arrestor sse D 6 Welder Generator Maintenance sess ene D 6 SIOFageu ose cantet pa eg ne ER PL ER diea D 6 cheek nn di vated sen rene Nr lens D 6 Brush Removal and Replacement u D 6 Troubleshooting U U uu u J Section E Safety Precautioris u e a B ade aaa Da nen E 1 How to Use Troubleshooting Guide nnn E 1 Troubleshooting Guide d eti eee ette Ate D e Ete ada E 2 Wiring Diagram amp Dimension Print Section F I II EI Em P330 Series 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS Ranger 275 Kohler Engine K1641 1 INPUT ENGINE Make Model Description Speed RPM Displacement Starting Capacities System 2 cylinder High Idle 3700 38 cu in 624 cc 12VDC battery Fuel 9 0 gal 20 0 HP
39. at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment METHOD OF PAYMENT Sorry No C O D Orders CHECKONE Address _ Please Invoice only if order is over 50 00 Check or Money Order Enclosed U S Funds only _ Credit Card Telephone Signature as it appears on Charge p 5 exe nate LI I USE THIS FORM TO ORDER Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 looks OR FREE INFORMATIVE CATALOGS Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 li incon Welding School Titles Price Code Quantity Cost ED 80 New Lessons in Arc Welding L 5 Information Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings 5450 H Educational Video Information Incentive Management IM UR es A New Approach to Industria Economics 9500 NA f Lames F Lincoln Arc Welding American Century of John C Lincoln 5500 AC J Foundation Book Information Welding Preheat Calculator 300 wes Pipe Welding Chars 5 SUB TOTAL Additional Shipping Costs f any uoo ea coul eee mm mm mm elem WARNING
40. ate with panels open Disconnect NEGATIVE BATTERY LEAD before servicing Keep guards in place Keep away from moving parts Only qualified personnel should install use Do not touch electrically live parts or service this equipment TO LN 742 INPUT 14 PIN E CABLE PLUG AMPHENOL K592 CONTROL CABLE TO WORK ELECTRODE ELECTRODE CABLE TO WIRE FEED UNIT TO WORK CAUTION ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE PLACE THE MODE SWITCH IN THE WIRE WELDING CV POSITION PLACE WELDER TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION IF OPTIONAL REMOTE OUTPUT CONTROL IS USED PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITIION PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 524095 5 RANGER 275 LN 8 CONNECTION DIAGRAM W
41. ations eaten aed se S a E IRR ER a A 1 Installation Instructions oerte Hei orco dece E RE A 3 Location and RR MERGE A 3 SONN Gaar UE EA A 3 Slacking m e teet Rep e eet dete A 3 Angle of Operations ritenere agde Cere ein rr Eka cede ie A 3 High Altitude Operation m dor eoe uQ hians ERO EIER ERR A 4 EN MEE UE T A 4 Additional Safety Precautions a A 4 Pre Operation Engine Service sien A 4 ttt eUam Uia IM LM MID A 4 Dt A 5 Battery Connections E A 5 rui A 5 Arfesler T eI dg A 5 El ctrical Connections mate nl lt rie e opes e sasaqa aspa A 6 Machine Ground Nge e Re ee q u eges Mes re OD a PEDE A 6 Welding Cable Connections ss A 6 Auxiliary Power Receptacles Plugs and Hand Held Equipment A 7 Circuit Breakers cs cedet bot oe etd e ires Ad een A 7 Premises Wiring sce ep em EA RR a ER A 7 EE Section B General Description rt ce te Sedit a Re batte pred B 1 Design Features Other Feat tres ead eit edo cn cc HR e de ic dep Recommended Applications sise B 2 litriitatlOris S eoe re cette to stet AE et dr dedi e ee B 2 Additional Safety Precautions ss B 2 Contro
42. complies with the National Electrical Code and all other applicable electrical codes The premises is isolated and no feedbacking into the utility system can occur Certain state and local laws require the premises to be isolated before the generator is linked to the premises Check your state and local requirements A double pole double throw transfer switch in con junction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter The following information and the connection diagram Figure A 1 can be used as a guide by the electrician for most applications to premises wiring 1 Install a double pole double throw switch between the power company meter and the premises dis connect The switch rating must be the same as or greater than the premises disconnect and service overcurrent protection 2 Take the necessary steps to assure that the load is limited to the capacity of the Ranger 275 by installing a 40 amp 240 volt double pole circuit breaker Maximum rated load for the 240 volt auxil iary is 38 amperes Loading above 38 amperes will reduce output voltage below the allowable 10 of rated voltage This may damage appliances or other motor driven equipment 3 Install a 50 amp 120 240 volt plug NEMA type 14 50 to the double pole circuit breaker using No 8 or larger 4 conductor cable of the desired length The 50 amp 120 240 volt plug is available in the o
43. dations Wash your hands with soap and water after handling used oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service sta tion or recycling center for reclamation Do not throw it in the trash pour it on the ground or down a drain CHANGING THE ENGINE OIL FILTER 1 Drain the engine oil and retighten the drain cap securely 2 Remove the oil filter and drain the oil into a suit able 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 filter socket tool to tighten the filter an additional 1 2 to 7 8 turn See Table D 5 for tightening torque specifications TABLE D 4 OIL FILTER TIGNTENING TORQUES Kohler OIL FILTER 10 ft lb 13 6NBm TORQUE 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 AIR CLEANER SERVICE A dirty air cleaner will restrict air flow to the carburetor To prevent carburetor malfunction service the air cleaner regularly Service more frequently when oper ating the engine in extremely
44. duplex recep tacles must use a three blade grounded type plug or an Underwriters Laboratories UL approved double insulation system with a two blade plug Lincoln offers an accessory plug kit that has the right type of plugs See the ACCESSORIES section of this manual for more information If you need ground fault protection for hand held equipment refer to the K896 1 GFCI Receptacle kit in the ACCESSORIES section of this manual for more information For recommended extension cord lengths and sizes see Table A 1 CIRCUIT BREAKERS The Ranger 275 machines are equipped with 50 amp circuit breakers on the 120 240 V receptacle and 15 amp circuit breakers on the 120 receptacles for over load protection Under high heat a breaker may tend to trip at lower loads than it would normally CAUTION Never bypass the circuit breakers Without overload protection the Ranger 275 could overheat and or cause damage to the equipment being used PREMISES WIRING The Ranger 275 is suitable for temporary standby or emergency power using the engine manufacturer s recommended maintenance schedule With its three wire grounded neutral generator it can be permanent ly installed as a standby power unit for 240 volt three wire single phase 38 ampere service WARNING Only a licensed certified trained electrician should install the machine to a premises or residential elec trical system Be certain that The installation
45. dusty areas A WARNING Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explosion could result Never run the engine without the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being drawn into the engine RANGER 275 LINCOLN 8 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 precleaner to air dry 4 Saturate the precleaner with new engine oil Squeeze out all excess oil 5 Reinstall the precleaner over the paper element 6 Reinstall the air cleaner cover Secure cover with the cover retaining knob Air Filter Paper Element Service 1 Loosen the cover retaining knob and remove the cover 2 Remove the precleaner from the paper element 3 Remove the element cover nut element cover and paper element 4 Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a new ele ment Handle new elements carefully do not use if the sealing surfaces are bent or damaged 5 When servicing the air cleaner check the air clean er base Make sure it is secur
46. e switch in Remote position to control output remotely Refer to Operation chapter for proper switch function Poor remote kit connection Check connections Faulty remote kit Replace if necessary Faulty control potentiometer or 4 Contact your Local Lincoln Authorized faulty PC board Field Service Facility for technical troubleshooting assistance No auxiliary power Open circuit breakers Reset breakers If breakers keep trip ping reduce power draw Faulty connections to auxiliary 2 Check connections receptacles GFCI tripped Clear any ground fault and reset GFCI circuit by pressing Reset button on the 120 V receptacle Faulty welding alternator or faulty 4 Contact your Local Lincoln Authorized PC board Field Service Facility for technical troubleshooting assistance Wire feeder does not work Wire Feeder Power circuit breaker 1 Reset connected to welder 14 pin amphe open nol Faulty wiring in control cable Repair or replace cable Faulty wire feeder Replace with known good one 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 275 LINCOLN DIAGRAMS F 1 Jequunu epoo 1u uudinb y SAID Ju uu oe d i e 104 3u unued q D2IA1 S
47. eas 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 Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY i PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Souda
48. ed and not bent or damaged Also check the element cover for dam age or improper fit Replace all damaged air cleaner components NOTE Before air cleaner reassembly make sure rub ber seal is in position around stud Inspect making sure it is not damaged and seals with the element cover 6 Reinstall the paper element precleaner element cover element cover nut and air cleaner cover Secure cover with the cover retaining knob SPARK PLUG SERVICE To ensure proper engine operation the spark plugs must be properly gapped and free of deposits 1 Remove the spark plug caps 2 Clean any dirt from around the spark plug bases 3 Use a plug wrench to remove the spark plugs WARNING The muffler becomes very hot during operation and remains hot for a while after stopping the engine Be careful not to touch the muffler while it is hot 4 Visually inspect the spark plugs Discard them if the insulator is cracked or chipped Clean the spark plugs with a wire brush if they are to be reused 5 Measure the plug gap with a feeler gauge Correct as necessary by bending the side electrode 6 Check that the spark plug washer is in good condi tion and thread the spark plug in by hand to pre vent cross threading 7 After the spark plug is seated tighten with a spark plug wrench to compress the washer If installing a new spark plug tighten 1 2 turn after the spark plug seats to compress the washer If reinstalli
49. exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only l IPrices include shipment by 4th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery pes Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 For North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you
50. ge A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger zones o l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on
51. he ground A WARNING Do not ground the machine to a pipe that carries explosive or combustible material When the Ranger 275 is mounted on a truck or a trail er the machine generator ground stud MUST be securely connected to the metal frame of the vehicle See Figure B 1 The ground stud is marked with the ground symbol If the Ranger 275 is connected to premises wiring such as a home or shop it must be properly connect ed to the system earth ground WELDING CABLE CONNECTIONS CABLE SIZE AND LENGTH Be sure to use welding cables that are large enough The correct size and length becomes especially important when you are welding at a distance from the welder Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the distance from the welder to the work and back to the welder Cable diameters are increased for long cable lengths to reduce voltage drops Lincoln Electric offers a welding accessory kit with the properly specified welding cables See the ACCESSORIES section of this manual for more infor mation INSTALLATION TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 300 Amps 100 Duty Cycle 1 0 AWG Cable Length 0 50 Ft 0 15 meters 1 0 AWG 50 100 Ft 15 39 meters 100 150 Ft 30 46 meters 2 0 AWG 150 200 Ft 46 61 meters 2 0 AWG 200 250 Ft 61 76 meters 3 0 AWG Table A 1 CABLE INSTALLATION Install the welding
52. ing the cover on the opposite side Operating the Ranger 275 without the cover in place will result in a higher noise level and no increase in machine output SPARK ARRESTER Gasoline engine mufflers may emit sparks when the engine is running Some federal state or local laws require spark arresters in locations where unarrested sparks could present a fire hazard Standard mufflers do not act as spark arresters When local laws require it a spark arrester must be installed on the machine and properly maintained An optional spark arrester kit is available for your Ranger 275 See the ACCESSORIES section of this manual for more information CAUTION An incorrect spark arrester may lead to damage to the engine or reduce performance RANGER 275 LINCOLN 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 MACHINE GROUNDING D Because the Ranger 275 creates its own power from its engine driven generator and if the machine is not connected to premises wiring home shop etc you do not need to connect the machine frame to an earth ground However for best protection against electri cal shock connect a heavy gauge wire 8 AWG or larger from the ground stud located on the bottom of the output panel See Figure B 1 to a suitable earth ground such as a metal pipe driven into t
53. is QUALITY product We want you to take pride in Thank You operating this product as much pride as we have in bringing this product to you 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 Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page Installation a s u ERE Section A Technical Specific
54. is mounted below the engine TABLE B 1 TYPICAL Ranger 275 FUEL CONSUMPTION K1641 1 Ranger 275 Kohler Engine Low Idle No Load 40 US gallons hour 2400 RPM 34 Imp gal hr 1 53 liters hour High Idle No Load 87 US gallons hour 3700 RPM 73 Imp gal hr 3 30 liters hour 210 Amps 25 Volts 1 27 US gallons hour DC Weld Output 1 06 Imp gal hr 4 82 liters hour 250 Amps 25 Volts 1 37 US gallons hour DC Weld Output 1 14 Imp gal hr 5 17 liters hour 275 Amps 25 Volts 1 44 US gallons hour DC Weld Output 1 20 Imp gal hr 5 45 liters hour 275 Amps 28 Volts 1 53 US gallons hour DC Weld Output 1 28 Imp gal hr 5 80 liters hour 9 000 watts 1 54 US gallons hour Auxiliary Power 1 28 Imp gal hr 5 81 liters hour RANGER 275 LINCOLN P B 6 OPERATION B 6 WELDING OPERATION A 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 ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous 23 Keep your head out of fumes Q Use ventilation or exhaust to remove fumes from breathing zone 4 MOVING PARTS can
55. ity or authorized engine service shop Battery does not stay charged Faulty battery Loose connections at battery or 2 Clean and tighten connections alternator Faulty engine alternator or charg 3 Consult authorized engine service er module 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 275 LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION Engine will not idle down to low 1 Idler switch in High idle position 1 Set switch to Auto 2 External load on welder or auxil 2 Remove all external loads iary power Faulty PC board idler solenoid 13 Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance Engine will not go to high idle when 1 Poor work lead connection tol1 Make sure work clamp is tightly con attempting to weld work nected to clean base metal Contactor switch is wrong 2 Set to Welding On when welding position without a control cable Refer to Operations chapter for proper use of this switch Faulty PC board Low idle speed 3 Contact your Local Lincoln Authorized set too low Field Service Facilit
56. level 1 Be sure the machine is on a level surface 2 Remove the engine oil dipstick and wipe it with a clean cloth Reinsert the dipstick and check the level on the dipstick 3 Add oil if necessary to bring the level up to the full mark Do not overfill 4 See Engine Owner s Manual for specific oil recom mendations m WARNING Check and fill the engine fuel tank GASOLINE can cause fire or 4 explosion Stop engine when fueling Do not smoke when fueling Do not overfill tank Avoid contact with skin or breathing of vapor Keep sparks and flame away from tank 1 Remove the fuel tank cap 2 Fill the tank approximately 4 inches 100 mm from the top of the filler neck to allow for fuel expansion observe the fuel gauge DO NOT FILL THE TANK TO THE POINT OF OVERFLOW 3 Replace the fuel tank cap and tighten securely 4 See Engine Owner s Manual for fuel recommenda tions STARTING THE ENGINE CAUTION Be sure all Pre Operation Maintenance has been per formed See the INSTALLATION section Remove all loads connected to the AC power recepta cles and the welder before starting the diesel engine To start the engine set the IDLER switch in the AUTO position Pull the choke control out lt gt Place the Engine Switch in the RUN Position Push the Start button and crank the engine until it starts Release the button as soon as the engine starts
57. ls and Settings eoe ue cim et ene trae tace E codec edd vue Ee Oye ede deae B 3 Welder Generator Controls u B 3 Engine Operation iis sheet tis Rare MUR Ailes theta au nich Ade atin B 4 Before Starting the Engine ss B 4 Starting the Engine ri tenen e ate e editer entiere B 4 Stopinig thie Erngilie nci gas o eines HERI EIU B 5 F uel Gonsumption Data iiie dote bee e aie tote B 5 Welding Operation on ec trei pete ee E edere d e B 6 Welder Controls Function and Operation u B 6 Stick Welding ue eno EROR E ADIRE ORO ua B 7 Pipe W eldlngi uu u E B 7 TIG W ldiig B 7 Wire Welding n ied e s ivi a eee eee B 8 Summary of Welding Processes and Machine Settings B 9 Auxiliary POWE eee event cer Ier cians a eet neve ooa etre thie ae o B 10 Simultaneous Welding and Power Loads B 10 ACCeSSOLFIGS tn ne nn ne Section C General Options Accessories C 1 TIG Welding Options Accessories C 1 Semiautomatic FCAW and MIG Welding Options Accessories C 2 Connection Diagrams for Accessories ssssssssseeeeeneeenns C 3 vii TABLE OF CONTENTS Page Maintenance is uu uu u J J Section D Safety Precautions ett et eA a Waya e tet ea D 1 Routine and Periodic Engine Maintenance D 1 Engine Maintenance P
58. m Spool Gun RANGER 275 LINCOLN 8 ACCESSORIES CONNECTION DIAGRAMS C 3 RANGER 275 LN 25 ACROSS THE ARC CONNECTION DIAGRAM WITH OPTIONAL K857 REMOTE CONTROL WARNING ELECTRIC SHOCK can kill MOVING PARTS can injure Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts or service this equipment 14 6 PIN OPTIONAL K857 AMPHENOL W AMPHENOL REMOTE CONTROL O Lo LN 25 WIRE FEEDER ELECTRODE WORK CLIP LEAD TO WORK TO WORK ELECTRODE CABLE WELDING CABLES MUST OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE PLACE THE MODE SWITCH IN THE WIRE WELDING CV POSITION IF REMOTE OUTPUT CONTROL IS USED PLACE LOCAL REMOTE SWITCH IN REMOTE POSITION PLACE THE WELDING TERMINALS SWITCH IN THE ALWAYS ON POSITION PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 524095 1 RANGER 275 LN 25 ACROSS THE ARC CONNECTION DIAGRAM WITH OPTIONAL K444 1REMOTE CONTROL WARNING ELECTRIC SHOCK can kill MOVING PARTS can iniure Do not opera
59. m at every indicated month or operating hour interval whichever comes first The diui E dE Change First Oil Change Engine Oil Filter Replace 1 Air Pre eser cal eser Air Cleaner Element 1 E rii ju an in _ Spark Arrestor Clean Optional Part boa VIS j Jj o bo Fuel Line Check Every 2 Years Replaceif necessary 1 Service more frequently when used in dusty areas and or at high ambient temperatures RANGER 275 LINCOLN 8 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 securely TABLE D 3 ENGINE OIL REFILL CAPACITIES Kohler 1 70US qt 1 41 Imp qt 1 60 liter 2 0 US qt 1 66Imp qt 1 90 liter Without oil filter replacement With oil filter replacement 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 SAE 10W 30 is recommended for general all temper ature use 5 F to 86 F 20 C to 30 C See Engine Owner s Manual for more specific information on Oil viscosity recommen
60. nce In general Mig welding performs best in the SOFT range and Innershield in the CRISP range LOCAL ei REMOTE Switch The toggle switch on the control panel labeled LOCAL REMOTE gives the operator the option of controlling the output at the welder control panel or at a wire feeder TIG amptrol or a K857 Remote Control that is connected to either the 6 pin or 14 pin amphe nol connector For remote control the toggle switch is set in the REMOTE position For control at the welder control panel the toggle Switch is set in the LOCAL position CONTACTOR Switch The toggle switch on the control panel labeled WELDING ON and CONTACTOR CONTROLLED is used to control the operation of the solid state con tactor which allows for the selection of Hot or Cold welding terminals With the switch in the WELDING ON position the contactor is closed and the welding terminals are always Hot With the switch in the CONTACTOR CONTROLLED position the contactor operation is controlled by an Amptrol Arc Start Switch or some other type of trig gering device through the use of a control cable con nected to the 6 pin or 14 pin amphenol RANGER 275 LINCOLN B 7 OPERATION 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 MO
61. nd add oil if indicated required maintenance Remove guards only when necessary and replace them when the ENGINE MAINTENANCE PARTS maintenance requiring their removal is complete Always use the greatest care when working near moving parts TABLE D 1 Do not put your hands near any rotating parts If Kohler CH 20 a problem cannot be corrected by following the Nea instructions take the machine to the nearest Oil Filter Kohler 1205001 Lincoln Field Service Shop FramPH3614 ELECTRIC SHOCK kill N not touch electrically live parts or Air Filter Kohler 4708303 Fram CA79 electrode with skin or wet clothing e insulate yourself from work and gms ground Air Filter Kohler 2408302 Always wear dry insulating gloves Pre Cleaner ENGINE EXHAUST can kill Fuel Filter Kohler 2505002 Use in open well ventilated areas or Fram G1 vent exhaust outside t AR SparkPlugs Champion RC12YC 030in 76 mm gap MOVING PARTS can injure Do not operate with enclosure guards off Oil capicity increases from 2 0 Qts to 2 1 Qts when using this filter A Stop engine before servicing Keep away from moving parts See additional warning information throughout this operator s manual and the Engine manual as well RANGER 275 LINCOLN D 2 MAINTENANCE D 2 TABLE D 2 KOHLER ENGINE MAINTENANCE SCHEDULE Regular Service Period 3 Each 5 Hrs 25 Hrs Every Every Use 100 Hrs 200 Hours ITEM Perfor
62. ng a used spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer TABLE D 6 SPARK PLUG INSTALLATION SPECIFICATIONS pce c Spark Plug Gap 030in 76 mm Spark Plug Torque 20ft Ib 27 N m CAUTION The spark plug must be securely tightened An improperly tight ened spark plug can become very hot and may cause engine dam age Use only the recommended spark plug or equivalent A spark plug which has an improper heat range may cause engine damage RANGER 275 LINCOLN 8 D 5 MAINTENANCE D 5 FUEL FILTER SERVICE WARNING When working on the fuel system 4 4 Keep naked lights away do not smoke Do not spill fuel 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 A WARNING OVERSPEED IS HAZARDOUS 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 BATTERY MAINTENANCE WARNING we GASES FROM BATTERY can explode e Keep sparks flame and cigarettes away from battery To prevent
63. o override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side AX Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 5 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground
64. om the arc rays 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 23 FUMES AND GASES can be dangerous 5 Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 5 c Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manuf
65. ot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety TRES minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt t
66. ot touch electrically live parts or service this equipment TO LN 25 INPUT 14 PIN Al CABLE PLUG AMPHENOL Q K626 XX INPUT CABLE ASSEMBLY TO WORK ELECTRODE ELECTRODE CABLE TO WIRE FEED UNIT TO WORK CAUTION ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A PLACE THE MODE SWITCH IN THE WIRE WELDING CV POSITION PLACE WELDER TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL IF OPTIONAL REMOTE OUTPUT CONTROL IS USED PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITIION PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 524095 3 RANGER 275 LN 7 CONNECTION DIAGRAM WARNING ELECTRIC SHOCK can kill MOVING PARTS can injure Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving par
67. oup d arc peut tre plus s v re qu un coup de soliel donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN TRANSFORMATEUR ET Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place v v for selecting th
68. ower The auxiliary power capacity rat ing in watts is equivalent to volt amperes at unity power factor The max permissible current of the 240 VAC output is 38 Amps The 240 VAC output can be split to provide two separate 120 VAC outputs with a max permissible current of 38 Amps per output to two separate 120 VAC branch circuits Output voltage is within 1096 at all loads up to rated capacity OPERATION B 10 The 120V duplex auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle NOTE The 240V receptacle has two circuits each of which measure 120 V to neutral but are of opposite polarities and cannot be paralleled SIMULTANEOUS WELDING AND POWER LOADS It must be noted that the above auxiliary power ratings are with no welding load Simultaneous welding and power loads are specified in the following table The permissible currents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply not both at the same time TABLE B 4 Ranger 275 SIMULTANEOUS WELDING AND POWER LOADS Welding Output Amps Available Auxiliary Power Watts Unity Power Factor Permissible Auxiliary Current in Amperes 240V Permissible Auxiliary Current in Amperes 120V RANGER 275 LINCOLN P
69. ptional power plug kit 4 Plug this cable in to the 50 amp 120 240 volt recep tacle on the Ranger 275 case front RANGER 275 LINCOLN 8 A 8 INSTALLATION A 8 Table A 1 Extension Cord Length Recommendations Current Voltage Load Maximum Allowable Cord Length in ft m for Conductor Size AWG Amps Volts Watts 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG 15 120 1800 30 9 40 12 75 23 125 38 175 53 300 91 15 240 3600 60 18 75 23 150 46 225 X 69 350 107 600 183 20 240 4800 60 18 100 30 175 53 275 84 450 137 25 240 600 90 27 150 46 225 69 250 76 30 240 7200 75 23 120 37 175 53 300 91 38 240 9000 100 30 150 46 250 76 Figure A 1 CONNECTION OF Ranger 275 TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR AE 60 Hz 3 Wire COMPANY Service METER NEUTRAL BUS LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES DISCONNECT AND SERVICE 40 AMP OVERCURRENT 240 VOLT PROTECTION DOUBLE POLE 50 AMP 120 240 CIRCUIT VOLT PLUG 240 VOLT BREAKER NEMA TYPE 14 50 1 a 50 AMP 120 240 VOLT Y De NOTE No 8 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS WARNING Connection of Ranger 275 to premises wiring must be done by a licensed
70. qIB lii sr au J sjaued ainsojdUS y Jo euo uo y paysed si opo 104 5 SUL 018011 366 91 9 siy Aq parao saulu2euu 104 93e1n22e jou juo e2uaJ9JaJ 10 SI SIUL 31ON WOY4 NMOHS SLIN3NOdWOO LNOWd 3572 11 3NION3 54015 VNIWH31 SIHL ONIGNNOUD RANGER 275 LINCOLN D WVYOVIG 5NIUIM F 2 S310H ONILNNOW 39VIluuvoOudaNn Fr 00 ecv F 00 0 DIAGRAMS lo 0 o o 0 o os es c Lc car co jc c a Sm lt Le 00 z ALdW3 ANVL 1803 ANY NI TIO HLIM ALIAVYS 30 U31N3O2 F 2 INIdd NOISN3MWIG ST c LVL6LW V l4VHS 40 b 00711 275 LINCOLN E NOTES RANGER 275 LINCOLN 8 Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure H
71. r voltage 16 ENGINE START PUSHBUTTON SWITCH 2 ARC CONTROL The ARC CONTROL is active in s starter solenoid contactor and fuel sole two modes STICK TIG and WIRE WELDING with different purposes in each mode 17 ENGINE CHOKE 3 MODE SWITCH Selects three possible modes of 18 AUTO IDLER SWITCH In the AUTO mode the welding operation 1 ce Stick TIG Welding 2 Pipe engine goes to low idle speed 12 seconds after a Welding and 3 CV Wire Welding welding or auxiliary power load is removed Engine 4 LOCAL REMOTE CONTROL SWITCH Allows the APRE operator to control welding output at the welding con 19 BATTERY CHARGER AMMETER trol panel or at a wire feeder TIG amptrol or a K857 remote control 20 ENGINE HOUR METER 5 CONTACTOR SWITCH The toggle switch labeled WELDING ON and CONTACTOR CONTROLLED is used to control the operation of the solid state out RANGER 275 LINCOLN B 4 OPERATION B 4 ENGINE OPERATION A WARNING 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 Read and understand all safety instructions included in the Engine Owner s manual that is shipped with your Ranger 275 BEFORE STARTING THE ENGINE gt Check the engine oil
72. sel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 Sem MAGNETIC FIELDS i may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with h
73. start stop controls are also on the case the engine battery circuit if a short develops Engine front See Figure B 1 and the explanations that follow will not crank if this circuit breaker is open 5 4 3 15 7 WIRE FEEDER POWER CIRCUIT BREAKER Opens the wire feeder circuit and disables the feeder if a fault is detected in the circuit 1 8 15 120 VOLT DUPLEX RECEPTACLES Connection point for supplying 120 volt power to oper 2 Q ate one or more electrical devices 16 9 50 AMP 120 240 VOLT RECEPTACLE Connection 5 6 point for supplying 240 volt power to operate one electrical device 19 10 WELD OUTPUT TERMINALS WITH FLANGE NUT 20 Provides the connection point for the electrode and work cables 7 11 GROUND STUD Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure 12 6 PIN AMPHENOL For attaching optional remote control equipment to the Ranger 275 13 14 PIN AMPHENOL For attaching wire feeder con trol cables to the Ranger 275 Includes contactor clo FIGURE B 1 vu control circuit wire feeder 115 42 OUTPUT PANEL CONTROLS R 14 WIRE FEEDER VOLTMETER POLARITY SWITCH WELDER GENERATOR CONTROLS matches polarity of wire feeder voltmeter to polarity of electrode See Figure B 1 for the location of the following features 15 ENGINE RUN STOP SWITCH Energizes engine cir it 1 OUTPUT CONTROL Allows full range adjustment of om welding current o
74. te with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving parts before servicing Only qualified personnel should install use Do not touch electrically live parts orservice this equipment 14 PIN 6 PIN AMPHENOL AMPHENOL OPTIONAL K444 1 re REMOTE CONTROL LN 25 WIRE FEEDER ELECTRODE WORK CLIP LEAD TO WORK TO WORK ELECTRODE CABLE WELDING CABLES MUST OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE PLACE THE MODE SWITCH IN THE WIRE WELDING CV POSITION IF REMOTE OUTPUT CONTROL IS USED PLACE LOCAL REMOTE SWITCH IN REMOTE POSITION PLACE THE WELDING TERMINALS SWITCH IN THE ALWAYS ON POSITION PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED 524095 2 RANGER 275 LINCOLN C4 ACCESSORIES CONNECTION DIAGRAMS C 4 RANGER 275 LN 25 WITH K624 1 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM WARNING ELECTRIC SHOCK can kill ma MOVING PARTS can injure Do not operate with panels open Keep guards in place Disconnect NEGATIVE BATTERY LEAD Keep away from moving parts before servicing Only qualified personnel should install use Do n
75. ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP5oUtRE K350C C F eu c EUR 18 e SH7IAE e S XACOER E MASH AH 7 44714 7 os iua bacs jua 5 axial oe ial uc Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten Nao opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas o FIYR H EXE RUE PSB ET RRA FE e SE m e AIR ati J pil gS jud ghil e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes
76. ts before servicing Only qualified personnel should install use Do not touch electrically live parts orservice this equipment TO LN 7 INPUT 14 PIN ae CABLE PLUG AMPHENOL K584 CONTROL CABLE lee OPTIONAL K857 E REMOTE CONTROL 6 PIN TO WORK ELECTRODE AMPHENOL ELECTRODE CABLE TO WIRE FEED UNIT TO WORK CAUTION ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MANUAL N B CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH POLARITY OF THE ELECTRODE CABLE N C PLACE THE MODE SWITCH IN THE WIRE WELDING CV POSITION N D IF OPTIONAL REMOTE OUTPUT CONTROL IS USED PLACE LOCAL REMOTE SWITCH IN REMOTE POSITION N E PLACE IDLER SWITCH IN HIGH POSITION 524095 4 275 LINCOLN 8 C 5 ACCESSORIES CONNECTION DIAGRAMS C 5 RANGER 275 LN 742 CONNECTION DIAGRAM WARNING ELECTRIC SHOCK can kill ma MOVING PARTS can injure Do not oper
77. ts 30 20 in Output 0 50 100 150 200 250 300 350 400 DC Output Current Amps RANGER 275 LINCOLN 8 A 3 INSTALLATION INSTRUCTIONS 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 ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill 23 Use in open well ventilated areas or E GA vent exhaust outside MOVING PARTS can injure 12 Do not operate with doors open or guards off Ms Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual Only qualified personnel should install use or service this equipment LOCATION AND VENTILATION 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 machine away from heat sources Do not place the engine end of the machine anywhere near hot engine exhaust from another machine or closer than two feet from a wall And of course make sure that engine exhaust is
78. use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 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 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers fr
79. y for technical troubleshooting assistance Engine will not go to high idle when 1 Auxiliary power load is less than 1 Idler may not respond with less than using auxiliary power 100 watts 100 watt load Set idler to High Faulty PC board Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance Engine does not develop full power 1 Fuel filter clogged Replace Air filter clogged Clean or replace Fouled spark plugs Clean or replace Valves out of adjustment Contact authorized engine service 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 275 LINCOLN 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual No welding power output 1 Contactor switch in wrong posi 1 Place switch in Welding On position tion when welding without control cable Refer to Operation chapter for proper Switch function Faulty welding alternator or faulty 2 Contact your Local Lincoln Authorized PC board Field Service Facility for technical troubleshooting assistance Welder has output but no control Local Remote switch is in wrong 1 Place switch in Control at Welder position position to control output at welder Plac

Lincoln Electric 275 Welder User Manual

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