Lincoln Electric 275 - Manuals

Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....

Page 3 - ii

ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...

Page 4 - iii

FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...

Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ

iv SAFETY iv 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 seco...

Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately

Thank You for selecting this QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringingthis product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay pa...

Page 7 - TABLE OF CONTENTS

vi TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A-1I...

Page 8 - vii

vii TABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1Routine and Periodic Engine Maint...

Page 9 - INSTALLATION; Kohler; RATED OUTPUT - WELDER; 15/42 Volt Auxiliary Power for Wire Feeders; PHYSICAL DIMENSIONS

A-1 INSTALLATION RANGER 275 A-1 TECHNICAL SPECIFICATIONS - Ranger 275 Kohler Engine (K1641-1) Make/Model Description Speed (RPM) Displacement Starting Capacities System Kohler 2 cylinder High Idle 3700 38 cu. in(624 cc) 12VDC battery Fuel: 9.0 gal. 20.0 HP @ Low Idle 2400 (Group 58, 435 (34 L) CH20 ...

Page 11 - INSTALLATION INSTRUCTIONS; Store the machine in a cool, dry place when it is; CANNOT

A-3 INSTALLATION RANGER 275 A-3 INSTALLATION INSTRUCTIONS SAFETY PRECAUTIONS Only qualified personnel should install,use, or service this equipment. LOCATION AND VENTILATION Whenever you use the Ranger 275, be sure that cleancooling air can flow through the machine’s engine andthe machine case. Avoi...

Page 12 - HIGH ALTITUDE OPERATION; Be sure machine is stable when lifting.; OIL

A-4 INSTALLATION RANGER 275 A-4 HIGH ALTITUDE OPERATION At high altitude, the standard carburetor air-fuel mix-ture will be too rich. Performance will decrease, andfuel consumption will increase. A very rich mixture willalso foul the spark plug and cause hard starting. High altitude performance can ...

Page 13 - FUEL; MUFFLER; CAUTION

A-5 INSTALLATION RANGER 275 A-5 FUEL Fill the fuel tank with clean, fresh regular grade lead-free gasoline. Observe the fuel gauge while filling toprevent overfilling. The Ranger 275 has a 9 U.S. gallon (7.5 Imp. Gal.,34L) fuel tank mounted below the generator. See theEngine Owners Manual for more d...

Page 14 - ELECTRICAL CONNECTIONS; MACHINE GROUNDING; CABLE SIZE AND LENGTH; CABLE INSTALLATION; TOTAL COMBINED LENGTH OF; Cable Length

A-6 INSTALLATION RANGER 275 A-6 ELECTRICAL CONNECTIONS See Figure B.1 in the OPERATION section of thismanual for location of the 120 and 240 volt recepta-c l e s , w e l d o u t p u t t e r m i n a l s , c i r c u i t b r e a k e r s a n dground stud. MACHINE GROUNDING Because the Ranger 275 creates...

Page 15 - CIRCUIT BREAKERS; PREMISES WIRING; The switch rating must be the same as

A-7 INSTALLATION RANGER 275 A-7 AU X I L I A RY P OW E R R E C E P TAC L E S ,PLUGS, AND HAND-HELD EQUIPMENT The control panel of the Ranger 275 features threeauxiliary power receptacles: See Figure B.1. • Two 15 amp, 120 volt duplex (double outlet) recepta- cles. • One 50 amp 120/240 volt single ou...

Page 16 - CONNECTION OF Ranger 275 TO PREMISES WIRING

A-8 INSTALLATION RANGER 275 A-8 Connection of Ranger 275 to premises wiring must be done by a licensed electrician and must complywith the National Electrical Code and all other applicable electrical codes. 240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRALB...

Page 17 - OPERATION; OPERATING INSTRUCTIONS; ELECTRIC SHOCK can kill.; GENERAL DESCRIPTION; FOR AUXILIARY POWER

B-1 OPERATION RANGER 275 B-1 OPERATING INSTRUCTIONS Read and understand this entire section before oper-ating your Ranger 275. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you havethoroughly read all operating and maintenance man-uals supplied with your machine. They include impor-...

Page 18 - OTHER FEATURES; RECOMMENDED APPLICATIONS; WELDER; LIMITATIONS; n o t r e c o m m e n d e d; ADDITIONAL SAFETY PRECAUTIONS

B-2 OPERATION B-2 RANGER 275 • One 50 amp 120 V single phase AC dual voltage power receptacle with two 50 amp circuit breakers.Supplies up to 38 amps of 240 V AC and up to 76amps of 120 V AC single phase auxiliary power perside to separate branch circuits (not in parallel).Allows easy connection to ...

Page 19 - CONTROLS AND SETTINGS; OUTPUT PANEL CONTROLS

B-3 OPERATION B-3 RANGER 275 CONTROLS AND SETTINGS A l l g e n e r a t o r / w e l d e r c o n t r o l s a r e l o c a t e d o n t h eOutput Control Panel of the machine case front. Idlercontrol, and start/stop controls are also on the casefront. See Figure B.1 and the explanations that follow. FIGU...

Page 20 - ENGINE OPERATION

B-4 OPERATION B-4 RANGER 275 ENGINE OPERATION D O N O T R U N T H E E N G I N E A T E X C E S S I V ESPEEDS. The maximum allowable high idle speedfor the Ranger 275 is 3750 RPM, no load. Do NOTadjust the governor screw on the engine. Severe per-sonal injury and damage to the machine can result if it...

Page 21 - STOPPING THE ENGINE; Engine; TYPICAL Ranger 275 FUEL CONSUMPTION

B-5 OPERATION B-5 STOPPING THE ENGINE Remove all welding and auxiliary power loads andallow the engine to run at low idle speed for a fewminutes to cool the engine. Stop the engine by placing the “Engine” switch in the“STOP” position. A fuel shut off valve is not required on the Ranger 275because th...

Page 22 - In this mode, increasing; WELDING OPERATION

B-6 OPERATION B-6 “ ARC CONTROL ” The “ARC CONTROL” is active in two modes: “STICK/TIG” and “WIRE WELDING” and has differentpurposes in each mode. It is not active in the “PIPE”mode. “ STICK/TIG ” mode: In this mode, the “ARC CON- TROL” knob sets the short circuit (arc force) currentduring stick wel...

Page 23 - MODE; STICK WELDING; b. Set the “IDLER” Switch to the “AUTO” position.

B-7 OPERATION B-7 When the triggering device is pressed the contactor isclosed and the welding terminals are “Hot.” When the triggering device is released the contactor isopened and the welding terminals are “Cold.” “ MODE ” Switch - Set to the desired process: STICK/TIG, PIPE, or WIRE FEED. “ WIRE ...

Page 24 - Table B.2 TYPICAL CURRENT RANGES; WIRE WELDING

B-8 OPERATION B-8 RANGER 275 Tungsten Electrode Diameter in. (mm) 2-155-20 15-80 70-150 150-250250-400 400-500500-750 750-1000 (3)(3)(3) 10-20 15-3025-40 40-5555-80 80-125 3-8 (2-4) 5-10 (3-5) 5-10 (3-5) 9-13 (4-6) 11-15 (5-7) 11-15 (5-7) 13-17 (6-8) 18-22 (8-10) 23-27 (11-13) TIG TORCH Nozzle Size ...

Page 25 - SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS

B-9 OPERATION B-9 RANGER 275 TABLE B.3 SUMMARY OF WELDING PROCESSES AND MACHINE SETTINGS CONTROL CABLE USED MODE SWITCH IDLER SWITCH OUTPUT CONTROL SWITCH CONTACTOR SWITCH ELECTRODE WHEN NOT WELDING TO START WELDING PROCESS STICK - CC TIG - CCK930-1 TIG MODULE /K936-1 CONTROL CABLE(With Amptrol) WIR...

Page 26 - AUXILIARY POWER; The 240V receptacle has two circuits, each of; Ranger 275 SIMULTANEOUS WELDING AND POWER LOADS

B-10 OPERATION B-10 RANGER 275 AUXILIARY POWER Start the engine and set the "IDLER" control switch tothe desired operating mode. Full power is availableregardless of the welding output settings, if no weldingcurrent is being drawn. The auxiliary power of the Ranger 275 consists of two15 Amp-...

Page 27 - ACCESSORIES; K703 Accessory Kit - Includes the following:

C-1 ACCESSORIES C-1 GENERAL OPTIONS / ACCESSORIES The following options/accessories are available foryour Ranger 275: K886-1 Canvas Cover - To protect the Ranger 275 when it is not being operated. Made from attractivered canvas material that is flame retardant, mildewresistant and water repellent. K...

Page 28 - - This portable unit can be used; NOTE; : Gas-shielded welding requires a Magnum; K488 SG Control Module; - Controls wire speed and

C-2 ACCESSORIES C-2 SEMIAUTOMATIC FCAW AND MIGWELDING OPTIONS / ACCESSORIES LN-25 Wire Feeder - This portable unit can be used for flux-cored arc welding (FCAW) and metal inert gaswelding (MIG). LN-7 Wire Feeder - Semiautomatic constant speed wire feeder. NOTE : Gas-shielded welding requires a Magnu...

Page 29 - ACCESSORIES - CONNECTION DIAGRAMS

C-3 C-3 RANGER 275 ACCESSORIES - CONNECTION DIAGRAMS 6 PIN AMPHENOL TO WORK 14 PIN AMPHENOL LN-25 N.E. PLACE THE WELDING TERMINALS SWITCH IN THE "ALWAYS ON" POSITION. N.C. PLACE THE MODE SWITCH IN THE "WIRE WELDING-CV" POSITION. N.F. PLACE IDLER SWITCH IN "AUTO" OR "HIGH&...

Page 34 - MAINTENANCE; ENGINE MAINTENANCE PARTS; SAFETY PRECAUTIONS; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n

D-1 MAINTENANCE D-1 ROUTINE AND PERIODIC ENGINEMAINTENANCE At the end of each day’s use, refill the fuel tank to min-imize moisture condensation in the tank. Running outof fuel tends to draw dirt into the fuel system. Also,check the crankcase oil level and add oil if indicated. ENGINE MAINTENANCE PA...

Page 35 - KOHLER ENGINE MAINTENANCE SCHEDULE

D-2 MAINTENANCE D-2 RANGER 275 TABLE D.2 KOHLER ENGINE MAINTENANCE SCHEDULE Regular Service Period (3) Each Use 5 Hrs. 25 Hrs. Every 100 Hrs. Every 200 Hours ITEM Perform at every indicated month or operating hour interval, whichever comes first. Engine Oil (1) Check Level O Change First Oil Change ...

Page 36 - CHANGING THE ENGINE OIL

D-3 MAINTENANCE D-3 CHANGING THE ENGINE OIL Drain the oil while the engine is warm to assure rapidand 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 wit...

Page 37 - KOHLER ENGINE; SPARK PLUG SERVICE

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 ofdetergent are eliminated. Squeeze...

Page 38 - FUEL FILTER SERVICE; BATTERY MAINTENANCE

D-5 MAINTENANCE D-5 FUEL FILTER SERVICE 1. Check the fuel filter for water accumulation or sedi- ment. 2. Replace the fuel filter if it is found with excessive water accumulation or sediment. ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS T h e m a x i m u m a l l o w a b l e h i g h i d l e s p e e d f ...

Page 39 - CHECKING ELECTROLYTE LEVEL; SERVICING OPTIONAL SPARK ARRESTOR

D-6 MAINTENANCE D-6 After cleaning, flush the outside of the battery, the bat-tery compartment, and surrounding areas with clearwater. 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 t...

Page 40 - TROUBLESHOOTING; Step 3. R E C O M M E N D E D C O U R S E O F; HOW TO USE TROUBLESHOOTING GUIDE

E-1 TROUBLESHOOTING E-1 RANGER 275 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Gui...

Page 41 - Local Lincoln Authorized Field Service Facility; PROBLEMS

RANGER 275 E-2 TROUBLESHOOTING E-2 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting a...

Page 44 - DIAGRAMS

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

Page 45 - DIMENSION PRINT

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

Page 46 - NOTES

Page 47 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals

Now Available...12th EditionThe Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P ...

Page 48 - ÇÃ

WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...