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Lincoln Electric RANGER 275, Operator'S Manual

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Ranger 275

OPERATOR’S MANUAL

IM606

July, 2001

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part.

DO

NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.

And, most

importantly, think before you act
and be careful.

For use with machines having Code Numbers:

10543

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

• World's Leader in Welding and Cutting Products •

Copyright © 2001 Lincoln Global Inc.

Summary of Contents for RANGER 275

Page 1: ...UIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 10543 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 l...

Page 2: ...R 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 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 availa...

Page 3: ...rical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h 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 ...

Page 4: ...event 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 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Weldin...

Page 5: ...s et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloign...

Page 6: ...e followed to avoid minor personal injury or damage to this equipment CAUTION 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 ...

Page 7: ... B General Description B 1 Design Features B 1 Other Features B 2 Recommended Applications B 2 Limitations B 2 Additional Safety Precautions B 2 Controls and Settings B 3 Welder Generator Controls B 3 Engine Operation B 4 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 Wel...

Page 8: ...lter D 3 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 Troubleshooting Guide E 2 Wiring Diagram Dimension Print ...

Page 9: ...3 in 19 1 in 42 0 in 469 lbs 770 mm 485 mm 1067 mm 212 kg OUTPUT GENERATOR Welding Output Volts at Rated Amps Duty Cycle1 Max OCV 3700 RPM CC Stick TIG Pipe and CV Wire Welding 275 Amps 28 volts 100 80 volts DC 300 Amps 25 volts 60 Auxiliary Power 2 9 000 Watts 60 Hz 120 240 Volts 100 Duty Cycle 115 42 Volt Auxiliary Power for Wire Feeders PHYSICAL DIMENSIONS 1 Duty cycle is based on a 10 minute p...

Page 10: ...A 2 INSTALLATION RANGER 275 A 2 TECHNICAL SPECIFICATIONS Ranger 275 K1641 1 ...

Page 11: ... not operate with doors open or guards off Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual WARNING 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 ...

Page 12: ...rame and should always be used when lifting the machine ADDITIONAL SAFETY PRECAUTIONS FALLING EQUIPMENT can cause injury Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting WARNING PRE OPERATION ENGINE SERVICE READ and UNDERSTAND the engine oper...

Page 13: ...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 pol...

Page 14: ...ecommended 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 WARNING Table A 1 ...

Page 15: ...nerator it can be permanent ly installed as a standby power unit for 240 volt three wire single phase 38 ampere service Only a licensed certified trained electrician should install the machine to a premises or residential elec trical system Be certain that The installation complies with the National Electrical Code and all other applicable electrical codes The premises is isolated and no feedbacki...

Page 16: ...UBLE POLE CIRCUIT BREAKER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 50 AMP 120 240 VOLT RECEPTACLE Figure A 1 CONNECTION OF Ranger 275 TO PREMISES WIRING Table A 1 Extension Cord Length Recommendations WARNING Current Voltage Load Maximum Allowable Cord Length in ft m for Conductor Size ...

Page 17: ...elder 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 pi...

Page 18: ...e 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 use demands LIMITATIONS The Ranger 275 is not recommended for any processes besides those that are normall...

Page 19: ...breaker is open 7 WIRE FEEDER POWER CIRCUIT BREAKER Opens the wire feeder circuit and disables the feeder if a fault is detected in the circuit 8 15 AMP 120 VOLT DUPLEX RECEPTACLES Connection point for supplying 120 volt power to oper ate one or more electrical devices 9 50 AMP 120 240 VOLT RECEPTACLE Connection point for supplying 240 volt power to operate one electrical device 10 WELD OUTPUT TER...

Page 20: ...ns WARNING WARNING STARTING THE ENGINE 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 Place the Engine Switch in the RUN Position Push the Start button and crank the ...

Page 21: ...0 Amps 25 Volts DC Weld Output 250 Amps 25 Volts DC Weld Output 275 Amps 25 Volts DC Weld Output 275 Amps 28 Volts DC Weld Output 9 000 watts Auxiliary Power K1641 1 Ranger 275 Kohler Engine 40 US gallons hour 34 Imp gal hr 1 53 liters hour 87 US gallons hour 73 Imp gal hr 3 30 liters hour 1 27 US gallons hour 1 06 Imp gal hr 4 82 liters hour 1 37 US gallons hour 1 14 Imp gal hr 5 17 liters hour 1...

Page 22: ...rol 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 o...

Page 23: ...l 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 l...

Page 24: ... TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 in 6 mm 5 5 16 in 8 mm 6 3 8 in 10 mm 7 7 16 in 11 mm 8 1 2 in 12 5 mm 10 5 8 in 16 mm 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 Ran...

Page 25: ...or 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 cont...

Page 26: ...es 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 ...

Page 27: ...lowing 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 o...

Page 28: ...lding 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 interfac...

Page 29: ...ore servicing Disconnect NEGATIVE BATTERY LEAD Do not touch electrically live parts Keep guards in place ELECTRODE TO WORK A RANGER 275 LN 25 ACROSS THE ARC CONNECTION DIAGRAM S24095 2 A N D IF REMOTE OUTPUT CONTROL IS USED PLACE LOCAL REMOTE SWITCH IN REMOTE POSITION N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS SEE OPERATING MAN...

Page 30: ...APACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE TO LN 25 INPUT K626 XX INPUT CABLE ASSEMBLY Do not operate with panels open Disconnect NEGATIVE BATTERY LEAD before servicing WARNING Do not operate with panels open Disconnect NEGATIVE BATTERY LEAD before servicing Do not touch electrically live parts ELECTRODE TO WORK A RANGER 275 LN 7 CONNECTION DIAGRAM S24095 4 N A WELDING CABLES M...

Page 31: ... CONTROL IS USED PLACE OUTPUT CONTROL SWITCH IN OUTPUT CONTROL REMOTE POSITIION APPLICATIONS SEE OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE Disconnect NEGATIVE BATTERY LEAD Do not touch electrically live parts 14 PIN AMPHENOL before servicing Do not operate with panels open TO WORK CAUTION THE ENGINE WELDER OPERATING MANUAL...

Page 32: ...TE EACH UNUSED LEAD INDIVIDUALLY RELAY TO CLOSE LEADS 2 4 N C PLACE THE MODE SWITCH IN THE WIRE WELDING CV POSITION 14 PIN TO WORK AMPHENOL TO MIN K867 K488 SG TO WORK CONTROL MODULE RECEPTACLE 14 PIN WIRE FEEDER RANGER 115V RECEPTACLE THE ENGINE WELDER OPERATING MANUAL K487 25 SPOOL GUN BE SURE THAT CONTROL MODULE MODE SLIDE SWITCH IS IN THE LINCOLN CONTACT CLOSURE POSITION BEFORE ATTEMPTING TO O...

Page 33: ... TERMINALS SWITCH TO REMOTELY CONTROLLED POSITION N F PLACE IDLER SWITCH IN AUTO OR HIGH IDLE POSITION AS DESIRED N B CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY FLOWMETER before servicing Do not touch electrically live parts REGULATOR TO GAS INPUT FITTING ARGON GAS K936 1 CONTROL CABLE CYLINDER CAUTION Keep guards in place Keep away from moving parts WARNING 14 PIN AMPHENOL Only q...

Page 34: ...lways use the greatest care when working near moving parts Do not put your hands near any rotating parts If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ...

Page 35: ...g hour interval whichever comes first Engine Oil 1 Check Level O Change First Oil Change O Engine Oil Filter 1 Replace O Air PreCleaner 1 Clean O Air Cleaner Element 1 Clean O Spark Plug Clean adjust O Spark Arrestor Optional Part Clean O Fuel Filter Check Visually O Fuel Line Check Replaceif necessary Every 2 Years 1 Service more frequently when used in dusty areas and or at high ambient temperat...

Page 36: ...move 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 torqu...

Page 37: ...he 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 The muffler becomes very hot during ...

Page 38: ...o new battery last 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 USING A BOOSTER connect positive lead to battery first then connect negative lead to negative battery lead at engine foot BATTERY ACID can burn eyes and skin Wear gloves and eye pro...

Page 39: ...ry 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 MUFFLER MAY BE HOT ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTOR DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTOR 1 Servic...

Page 40: ...neral 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 HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment ma...

Page 41: ...y PC board or ignition system 1 Low oil level 2 Faulty oil pressure switch or other engine component 3 Open rotor circuit 1 Faulty battery 2 Loose connections at battery or alternator 3 Faulty engine alternator or charg er module 1 Contact your Local Lincoln Authorized Field Service Facility 1 Charge Battery 2 Inspect clean and tighten 3 Contact authorized engine Service Shop 4 Re set If it contin...

Page 42: ...on to work 2 Contactor switch is in wrong position 3 Faulty PC board Low idle speed set too low 1 Auxiliary power load is less than 100 watts 2 Faulty PC board 1 Fuel filter clogged 2 Air filter clogged 3 Fouled spark plugs 4 Valves out of adjustment 1 Set switch to Auto 2 Remove all external loads 3 Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assista...

Page 43: ...FCI tripped 4 Faulty welding alternator or faulty PC board 1 Wire Feeder Power circuit breaker open 2 Faulty wiring in control cable 3 Faulty wire feeder 1 Place switch in Welding On position when welding without control cable Refer to Operation chapter for proper switch function 2 Contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance 1 Place switch ...

Page 44: ... LOCAL POS W2 W3 STATOR WELD WINDINGS W1 7 9 STATOR FIELD WINDING 7 9 8 16 11 12 67 68 69 25A 25 23 23A PIPE CC 218 214 220 222 22 21 77 76 75 277 278 250 2B 248 212 261 260 213 215 31A STARTER CR1 STARTER SOLENOID 12 VOLT BATTERY SWITCH HOUR METER S1 SOLENOID FUEL SHUTOFF POSITION S1 SHOWN IN RUN OIL PRESSURE 209B 209A 208D IGNITION MODULE 5J 209 211C GND H AM1 208A S2 START BUTTON 5J 221 IDLER C...

Page 45: ...ANGER 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 RANGER 275 ...

Page 47: ...16 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location Orders 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 Prices include shipment by 4thClass Book Rate ...

Page 48: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque 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 vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 49: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 50: ...s 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 World s Leader in Welding and Cutting Products ...

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