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Lincoln Electric RANGER 275 Operator's Manual

Lincoln electric welder user manual.
Also See for RANGER 275:
Specification sheet - 8 pages
User manual - 48 pages
For use with machines having Code Numbers:
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
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:
• 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
RETURN TO MAIN MENU
Ranger 275
10543
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2001 Lincoln Global Inc.
IM606
July, 2001

   Related Manuals for Lincoln Electric RANGER 275

   Summary of Contents for Lincoln Electric RANGER 275

  • Page 1

    • 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 RETURN TO MAIN MENU Ranger 275 10543 Copyright © 2001 Lincoln Global Inc. IM606...

  • Page 2

    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.

  • Page 3

    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.

  • Page 4

    WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

  • Page 5

    PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.

  • Page 6

    Thank 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.

  • Page 7: Table Of Contents

    Before Starting the Engine ...B-4 Starting the Engine...B-4 Stoping the Engine ...B-5 Fuel Consumption Data ...B-5 Welding Operation...B-6 Welder Controls - Function and Operation...B-6 Stick Welding ...B-7 Pipe Welding ...B-7 TIG Welding ...B-7 Wire Welding ...B-8 Summary of Welding Processes and Machine Settings ...B-9 Auxiliary Power...B-10...

  • Page 8: Table Of Contents

    Air Cleaner Service ...D-3 Spark Plug Service ...D-4 Fuel Filter Service ...D-5 Engine Adjustments ...D-5 Battery Maintenance ...D-5 Servicing Optional Spark Arrestor ...D-6 Welder / Generator Maintenance ...D-6 Storage ...D-6 Cleaning...D-6 Brush Removal and Replacement ...D-6 Troubleshooting ...Section E Safety Precautions...E-1 How to Use Troubleshooting Guide...E-1...

  • Page 9: Technical Specifications

    TECHNICAL SPECIFICATIONS - Ranger 275 Kohler Engine (K1641-1) Make/Model Description Kohler 2 cylinder 20.0 HP @ CH20 3600 RPM Full Load Gas Engine Welding Output CC Stick/TIG, Pipe and CV Wire Welding 275 Amps 300 Amps 115/42 Volt Auxiliary Power for Wire Feeders...

  • Page 10

    INSTALLATION TECHNICAL SPECIFICATIONS - Ranger 275 (K1641-1) RANGER 275...

  • Page 11: Installation Instructions, Location And Ventilation, Storing, Stacking, Angle Of Operation

    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.

  • Page 12: High Altitude Operation, Lifting, Additional Safety Precautions, Pre-operation Engine Service

    • Keep sparks and flame away from the fuel tank. ------------------------------------------------------------------------ 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.

  • Page 13: Fuel, Battery Connections, Muffler, Spark Arrester

    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.

  • Page 14: Electrical Connections, Machine Grounding, Welding Cable Connections

    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.

  • Page 15: Auxiliary Power Receptacles, Plugs, And Hand-held Equipment, Circuit Breakers, Premises Wiring

    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.

  • Page 16

    VOLT PLUG NEMA TYPE 14-50 50 AMP, 120/240 VOLT RECEPTACLE Connection of Ranger 275 to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes. INSTALLATION Table A.1...

  • Page 17: General Description, Design Features

    Only qualified personnel should operate this equip- ment. OPERATION 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;...

  • Page 18: Other Features, Recommended Applications, Limitations, Additional Safety Precautions

    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 use demands. OPERATION LIMITATIONS • The Ranger 275 is not recommended for any...

  • Page 19: Controls And Settings, Welder / Generator Controls

    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- sure circuit, remote control circuit, wire feeder 115/42 volt power source).

  • Page 20: Engine Operation, Before Starting The Engine, Starting The Engine

    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.

  • Page 21

    Auxiliary Power OPERATION Stop the engine by placing the “Engine” switch in the “STOP” position. A fuel shut off valve is not required on the Ranger 275 because the fuel tank is mounted below the engine. ------------------------------------------------------------------------ TABLE B.1 K1641-1 Ranger 275 Kohler Engine .40 US gallons/hour...

  • Page 22: Welding Operation, Welder Controls - Function And Operation

    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.

  • Page 23: Stick Welding, Pipe Welding, Tig Welding

    OPERATION 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 60% duty cycle and 250A at a 80% duty cycle.

  • Page 24: Wire Welding

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

  • Page 25: Summary Of Welding Processes And Machine Settings

    RANGER 275 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.

  • Page 26: Auxiliary Power, Simultaneous Welding And Power Loads

    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.

  • Page 27: General Options / Accessories, Tig Welding Options / Accessories

    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.

  • Page 28: Semiautomatic Fcaw And Mig Welding Options / Accessories

    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 Magnum Spool Gun. RANGER 275...

  • Page 29

    ACCESSORIES - CONNECTION DIAGRAMS RANGER 275 / LN-25 ACROSS THE ARC CONNECTION DIAGRAM WITH OPTIONAL K857 REMOTE CONTROL Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts. 14 PIN AMPHENOL...

  • Page 30

    ACCESSORIES - CONNECTION DIAGRAMS RANGER 275 / LN-25 WITH K624-1 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts. 14 PIN AMPHENOL...

  • Page 31

    ACCESSORIES - CONNECTION DIAGRAMS RANGER 275 / LN-742 CONNECTION DIAGRAM Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts. 14 PIN AMPHENOL ELECTRODE 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.

  • Page 32

    RELAY TO CLOSE LEADS 2 & 4. N.F. REFER TO POWER SOURCE INSTRUCTION MANUAL FOR MAXIMUM AUXILIARY CURRENT DRAW. RANGER 275 / K691-10 / K488 / K487 SPOOL GUN CONNECTION DIAGRAM Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing.

  • Page 33

    ACCESSORIES - CONNECTION DIAGRAMS RANGER 275 / K930 TIG MODULE / Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD before servicing. Do not touch electrically live parts. REGULATOR FLOWMETER ARGON GAS TO GAS CYLINDER INPUT FITTING K936-1...

  • Page 34: Safety Precautions, Routine And Periodic Engine Maintenance, Engine Maintenance Parts

    Oil Filter Air Filter Air Filter Pre-Cleaner Fuel Filter Spark Plugs * Oil capicity increases from 2.0 Qts. to 2.1 Qts when using this filter. RANGER 275 TABLE D.1 Kohler CH 20 Kohler 1205001 Fram PH3614* Kohler 4708303 Fram CA79...

  • Page 35: Engine Maintenance Schedule

    (Replace if necessary) (1) Service more frequently when used in dusty areas and or at high ambient temperatures. MAINTENANCE TABLE D.2 Each 5 Hrs. 25 Hrs. First Oil Change Every 2 Years RANGER 275 Every Every 100 Hrs. 200 Hours...

  • Page 36: Changing The Engine Oil, Changing The Engine Oil Filter, Air Cleaner Service

    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 TABLE D.4 Kohler 10 ft-lb, (13.6 Nßm) WARNING...

  • Page 37: Spark Plug Service

    Use only the recommended spark plug or equivalent. A spark plug which has an improper heat range may cause engine damage. ------------------------------------------------------------------------------------------ RANGER 275 WARNING TABLE D.6 Kohler .030 in. (.76 mm) 20 ft.

  • Page 38: Fuel Filter Service, Engine Adjustments, Battery Maintenance

    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 WARNING...

  • Page 39: Servicing Optional Spark Arrestor, Welder / Generator Maintenance, Storage, Cleaning, Brush Removal And Replacement

    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.

  • Page 40: How To Use Troubleshooting Guide, Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE 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.

  • Page 41

    1. Faulty battery. 2. Loose connections at battery or alternator. 3. Faulty engine alternator or charg- er module. CAUTION RANGER 275 RECOMMENDED COURSE OF ACTION 1. Contact your Local Lincoln Authorized Field Service Facility. 1. Charge Battery. 2. Inspect, clean and tighten.

  • Page 42

    1. Fuel filter clogged. 2. Air filter clogged. 3. Fouled spark plugs. 4. Valves out of adjustment. CAUTION RANGER 275 RECOMMENDED COURSE OF ACTION 1. Set switch to Auto. 2. Remove all external loads. 3. Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance.

  • Page 43

    1. Wire Feeder Power circuit breaker open. 2. Faulty wiring in control cable 3. Faulty wire feeder. CAUTION RANGER 275 RECOMMENDED COURSE OF ACTION 1. Place switch in "Welding On" position when welding without control cable. Refer to Operation chapter for proper switch function.

  • Page 44

    DIAGRAMS BLACK BLACK WHITE WHITE GREEN GREEN GREEN GREEN GREEN RANGER 275...

  • Page 45

    DIAGRAMS RANGER 275...

  • Page 46

    NOTES RANGER 275...

  • Page 47

    Address: Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Titles: Price New Lessons in Arc Welding $5.00...

  • Page 48

    ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

  • Page 49

    ● ● Keep your head out of fumes. Turn power off before servicing. ● Use ventilation or exhaust to remove fumes from breathing zone. ● Los humos fuera de la zona de res- ● Desconectar el cable de ali- piración. mentación de poder de la máquina ●...

  • Page 50

    • 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...

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