Lincoln Electric RANGER 275 User Manual

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IM606

Ranger 275	July, 2001
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 thoughtful 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

Copyright © 2001 Lincoln Global Inc.

•World's Leader in Welding and Cutting Products •

•Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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 & 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.

____________________________________________________

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes

outdoors.

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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 vaporizing on contact with hot 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.

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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.

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1.e. In some cases it may be necessary to remove safety 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.

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1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

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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.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

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.

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.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii		SAFETY		ii

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) use the following equipment:

•Semiautomatic DC Constant Voltage (Wire) Welder.

•DC Manual (Stick) Welder.

•AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. 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.

3.e. Ground the work or metal to be welded to a good electrical (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.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover 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. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. 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.

FUMES AND GASES can be dangerous.

5.a. 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.

5.d. Read and understand the manufacturer’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

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SAFETY

iii

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. 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 Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. 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.

6.d. 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 “Recommended

Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. 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.

6.g. 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 circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER may explode

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.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•Away from areas 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.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “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.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer’s recommendations.

Mar ‘95

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SAFETY

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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 suivantes:

Sûreté Pour Soudage A L’Arc

1.Protegez-vous contre la secousse électrique:

a.Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b.Faire trés 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 couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c.Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le refroidir.

e.Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f.Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

2.Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3.Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a.Utiliser un bon masque avec un verre filtrant approprié ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b.Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au soudage à l’aide d’écrans appropriés 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, pantalons 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.Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7.Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8.S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9.Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10.Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11.Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1.Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2.Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3.Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4.Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

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Thank You

v

for selecting this QUALITY product. We want you to take pride in 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 & Number _____________________________________

Code & 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:

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			vi
			Page
		Installation.......................................................................................................................	Section A
		Technical Specifications.......................................................................................................	A-1
		Installation Instructions.........................................................................................................	A-3
		Location and Ventilation................................................................................................	A-3
		Storing...........................................................................................................................	A-3
		Stacking ........................................................................................................................	A-3
		Angle of Operation ........................................................................................................	A-3
		High Altitude Operation .................................................................................................	A-4
		Lifting.............................................................................................................................	A-4
		Additional Safety Precautions .......................................................................................	A-4
		Pre-Operation Engine Service..............................................................................................	A-4
		Oil..................................................................................................................................	A-4
		Fuel ...............................................................................................................................	A-5
		Battery Connections......................................................................................................	A-5
		Muffler ...........................................................................................................................	A-5
		Spark Arrester ...............................................................................................................	A-5
		Electrical Connections..........................................................................................................	A-6
		Machine Grounding.......................................................................................................	A-6
		Welding Cable Connections..........................................................................................	A-6
		Auxiliary Power Receptacles, Plugs, and Hand-Held Equipment ........................................	A-7
		Circuit Breakers....................................................................................................................	A-7
		Premises Wiring ...................................................................................................................	A-7
		Operation.........................................................................................................................	Section 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 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
		Simultaneous Welding and Power Loads ...................................................................	B-10
		Accessories .....................................................................................................	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 ..................................................................	C-3

vii	TABLE OF CONTENTS

		Page
	Maintenance ....................................................................................................	Section D
	Safety Precautions ................................................................................................	D-1
	Routine and Periodic Engine Maintenance ...........................................................	D-1
	Engine Maintenance Parts..............................................................................	D-1
	Engine Maintenance Schedule .......................................................................	D-2
	Changing the Engine Oil .................................................................................	D-3
	Changing the Engine Oil Filter ........................................................................	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................................................................	Section F
	Parts Lists ....................................................................................................	P330 Series

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS - Ranger 275 Kohler Engine (K1641-1)

		INPUT - ENGINE
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	3600 RPM	Full Load 3400			cold crank amps)
				Bore x Stroke
	Full Load
Gas Engine				3.03” x 2.64”	25 A. Alternator
				(77 mm x 67 mm)		Oil: 2.0 Qts.
						(1.9 L)

RATED OUTPUT - WELDER

	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%

OUTPUT - GENERATOR

Auxiliary Power 2

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
30.3 in.	19.1 in.	42.0 in.	469 lbs.
770 mm	485 mm	1067 mm	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 ± 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.

RANGER 275

A-2	INSTALLATION	A-2

TECHNICAL SPECIFICATIONS - Ranger 275 (K1641-1)

RANGER 275

A-3	INSTALLATION	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.

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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.

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ENGINE EXHAUST can kill.

•Use in open, well ventilated areas or

vent exhaust outside.

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MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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See additional warning information at front of this operator’s manual.

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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 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.

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 construction 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 whenever 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 direction. If you do operate it at a slight angle, be sure 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

A-4	INSTALLATION	A-4

HIGH ALTITUDE OPERATION

At high altitude, the standard carburetor air-fuel mixture 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 3.5% 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 lbs/212 kg. A lift bail is mounted to the machine frame and should always be used when lifting the machine.

PRE-OPERATION ENGINE SERVICE

CAUTION

READ and UNDERSTAND the engine operating and maintenance instructions supplied with this machine.

------------------------------------------------------------------------

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.

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OIL

ADDITIONAL SAFETY PRECAUTIONS

WARNING

FALLING EQUIPMENT can cause injury.

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.

●Do not lift this machine using lift For more information on oil viscosity and service con- bale if it is equipped with a heavy ditions, see the MAINTENANCE section of this manu-

accessory such as trailer or gas cylinder.

●Lift only with equipment of adequate lifting capacity.

●Be sure machine is stable when lifting.

al and the engine Operator’s Manual.

RANGER 275

A-5	INSTALLATION	A-5

FUEL

Fill the fuel tank with clean, fresh regular grade leadfree 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

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.

●CONNECTING A BATTERY CHARGER — remove battery from welder by disconnecting negative 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 protection and be careful when working near battery.

● 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 battery may require a booster charge. Be sure to use the correct polarity when charging the battery.

MUFFLER

CAUTION

Shut off the machine and allow the muffler to cool before touching the muffler.

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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 installing 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.

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RANGER 275

A-6	INSTALLATION	A-6

ELECTRICAL CONNECTIONS

See Figure B.1 in the OPERATION section of this manual for location of the 120 and 240 volt receptacles, weld output terminals, circuit breakers and ground stud.

MACHINE GROUNDING

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 electrical 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 the ground.

WARNING

Do not ground the machine to a pipe that carries explosive or combustible material.

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When the Ranger 275 is mounted on a truck or a trailer, 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 connected 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 information.

TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES

		Cable Length			Cable Size for
					300 Amps
					100% Duty Cycle
		0-50 Ft. (0-15 meters)			1/0 AWG
		50-100 Ft. (15-39 meters)			1/0 AWG
		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 cables to your Ranger 275 as follows. 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 requirement for the welding process being used determines 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 terminal connection. Keep the cables isolated and separate from one another.

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RANGER 275

A-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) receptacles.

•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 electrical equipment connected to the 120V duplex receptacles must use a three-blade, grounded type plug or an Underwriter’s 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 overload 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.

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PREMISES WIRING

The Ranger 275 is suitable for temporary, standby, or emergency power using the engine manufacturer’s recommended maintenance schedule. With its threewire grounded neutral generator, it can be permanently 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 electrical system. Be certain that:

•The installation 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 conjunction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter.

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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 disconnect. 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 auxiliary 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 1450) 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 optional power plug kit.

4.Plug this cable in to the 50 amp 120/240 volt receptacle on the Ranger 275 case front.

RANGER 275