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For use with machines having Code Numbers:
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
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
Ranger 200
10646
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
IM660
January,2000
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Table of Contents
Related Manuals for Lincoln Electric Ranger 200
Summary of Contents for Lincoln Electric Ranger 200
- Page 1 January,2000 10646 For use with machines having Code Numbers: This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci cations and availability of optional features may have changed. Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind.
- 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 SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
- Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
- Page 5 SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté...
- Page 6 QUALITY product by Lincoln Electric. We want you Thank You to take pride in operating this Lincoln Electric Company 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.
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Page 7: Table Of Contents
TABLE OF CONTENTS Page Installation........................Section A Technical Specifications .......................A-1 Installation Instructions......................A-2 Location and Ventilation....................A-2 Storing ...........................A-2 Stacking ........................A-2 Tilting..........................A-2 High Altitude Operation ....................A-3 Lifting..........................A-3 Additional Safety Precautions ..................A-3 Pre-Operation Engine Service....................A-3 Oil ..........................A-3 Fuel ..........................A-4 Engine Coolant......................A-4 Battery Connections ......................A-4 Muffler Outlet Pipe ......................A-4 Spark Arrester .......................A-4 Electrical Connections ......................A-5... - Page 8 TABLE OF CONTENTS Page Maintenance ....................Section D Welder / Generator Maintenance ................D-5 Storage ......................D-5 Cleaning......................D-5 Brush Removal and Replacement ..............D-5 Troubleshooting ....................Section E How to Use Troubleshooting Guide...............E-1 Troubleshooting Guide ..................E-2 Troubleshooting Guide ..................E-3 Troubleshooting Guide ..................E-4 Wiring Diagram.....................Section F-1 Dimension Print ....................Section F-2 Parts Lists....................P351 SERIES...
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Page 9: Installation
INSTALLATION TECHNICAL SPECIFICATIONS - Ranger 200 (K1724-1) INPUT - GASOLINE ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System Kohler 1 cylinder Low Idle 2500 26 cu. in 12VDC Battery & Fuel: 12 gal. Command (Cast Iron Liner) Starter CH15 OHV... -
Page 10: Installation Instructions
And of course, make sure that engine exhaust is ven- tilated to an open, outside area. The RANGER 200 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. -
Page 11: High Altitude Operation
Some of the The RANGER 200 is shipped with the engine filled factors to be considered are as follows: with SAE 10W-30 oil. CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE. -
Page 12: Fuel
The RANGER 200 is shipped with the negative bat- tery cable disconnected. Make certain that the RUN- The RANGER 200 has a 12 gallon (45.4 liter) fuel STOP switch is in the STOP position. Remove the two tank with a top fill and fuel gauge mounted on the con- screws from the rear battery tray using a screwdriver trol panel. -
Page 13: Electrical Connections
Install the welding cables to your RANGER 200 as fol- ground. See further connection instructions in the lows. See Figure B.1 for location of parts. -
Page 14: Auxiliary Power Receptacles And Plugs
AUXILIARY POWER RECEPTACLES & PREMISES WIRING PLUGS WARNING The auxiliary power of the RANGER 200 consists of two 20 Amp-120 VAC (5-20R) duplex receptacles and Only a licensed, certified, trained electrician should one 50 Amp 120/240 VAC (14-50R) receptacle. The... - Page 15 INSTALLATION Figure A.1 CONNECTION OF RANGER 200 TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 120 VOLT 60 Hz. COMPANY 3-Wire 120 VOLT Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.
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Page 16: Operation
OPERATION GENERAL DESCRIPTION CONTROLS AND SETTINGS The Ranger 200 is a gasoline engine powered DC All generator/welder controls are located on the stick welding power source and 120/240 volt AC Output Control Panel of the machine case front. See power generator. The engine drives a generator that figure on page B-2 and the explanations that follow. -
Page 17: Engine Controls
A. When switched from HIGH to AUTO or after start- ing the engine, the engine will operate at full speed 5. RUN/STOP SWITCH: RUN position energizes for approximately 12 seconds and then go to low the engine prior to starting. STOP position stops the idle speed. RANGER 200... -
Page 18: Engine Operation
NOTE: A fuel shut off valve is not required on the 1. Remove the fuel tank cap. Ranger 200 because the fuel tank is mounted below the engine. 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.) -
Page 19: Welding Operation
OPERATION TABLE B.1 Stick Welding The RANGER 200 can be used with a broad range of TYPICAL RANGER 200 FUEL CONSUMPTION DC stick electrodes. TIG Welding RUNNING KOHLER CH 15 15 HP@3600 The RANGER 200 can be used for limited DC TIME 12 GAL. -
Page 20: Simultaneous Welding And Auxiliary Powerloads
The permissible cur- rents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply (not both at the same time). Ranger 200 Simultaneous Welding and Power Loads Permissible Auxiliary Welding... -
Page 21: Accessories
Cooltong 300 electrode holder. Cables are rated at 225 amps, 40% duty cycle. K802-N POWER PLUG KIT Provides four 120 volt plugs rated at 20 amps each and one dual voltage, full KVA plug rated at 120/240 volts, 50 amps. RANGER 200... -
Page 22: Maintenance
Kohler 5208301 3. Refill to the upper limit mark on the dipstick with the recommended oil. Tighten the oil filler cap securely. Fuel Filter Kohler 2505002, Fram G1 Spark Plug Champion RC12YC (.040” Gap) Battery BCI Group 58 (435) RANGER 200... -
Page 23: Routine And Periodic Engine Maintenance
5. Reinstall the pre-cleaner over the paper element. 3. Clean the filter mounting base, and coat the gasket of the new oil filter with clean engine oil. 6. Reinstall the air cleaner cover. Secure cover with the cover retaining knob. RANGER 200... -
Page 24: Air Filter Paper Element
Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service 5. Measure the plug gap with a feeler gauge. Correct Shop. as necessary by bending the side electrode. -Spark Plug Gap (.040 in.) (1.0 mm) RANGER 200... -
Page 25: Battery Maintenance
Improper polarity can damage the charging GASES FROM BATTERY can explode. circuit. The RANGER 200 positive (+) battery terminal Keep sparks, flame and cigarettes has a red terminal cover. -
Page 26: Welder/Generator Maintenance
MAINTENANCE Welder/Generator Maintenance STORAGE: Store the RANGER 200 in clean, dry pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air. Do this at least once a week in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT: It’s nor- mal for the brushes and slip rings to wear and darken slightly. -
Page 27: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. - Page 28 Shop. 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 200...
- Page 29 4. Contact authorized Engine Service Shop. 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 200...
- Page 30 FACILITY for technical trou- bleshooting assistance. 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 200...
- Page 31 DIAGRAMS...
- Page 33 NOTES...
- Page 34 NOTES RANGER 200...
- Page 35 Month Year USE THIS FORM TO ORDER: Order from: 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 BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or, Lincoln Welding School...
- Page 36 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
- Page 37 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
- Page 38 • 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...