Lincoln Electric IM660 User Manual

Ranger 200

OPERATOR’S MANUAL

IM660

January,2000

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.

For use with machines having Code Numbers:

10646

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

• World's Leader in Welding and Cutting Products •

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

RETURN TO MAIN MENU

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.

____________________________________________________

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.

____________________________________________________

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.

____________________________________________________

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.

___________________________________________________

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.

___________________________________________________

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.

i

SAFETY

i

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.

WARNING

Mar ‘95

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.

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

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 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 Diesel Engines

The Above For Gasoline Engines

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 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.

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.

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

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.

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.

iii

SAFETY

iii

Mar ‘95

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.

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 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

Thank You

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this 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 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.

This statement appears where the information must be 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 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.

vv

vi

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

Machine Grounding.......................................................................................................A-5

Welding Cable Connections..........................................................................................A-5

Auxiliary Power Receptacles and Plugs...............................................................................A-6

Premises Wiring ...................................................................................................................A-7

Operation.........................................................................................................................Section B

General Description..............................................................................................................B-1

Design Features...................................................................................................................B-1

Recommended Applications.................................................................................................B-1

Additional Safety Precautions .............................................................................................B-1

Controls and Settings..................................................................................................................B-1

Welder Controls ............................................................................................................B-2

Engine Controls.............................................................................................................B-2

Engine Operation .................................................................................................................B-3

Before Starting the Engine............................................................................................B-3

Starting the Engine........................................................................................................B-3

Stoping the Engine........................................................................................................B-3

Welding Operation................................................................................................................B-4

DC Stick Welding ..........................................................................................................B-4

DCTIG Welding.............................................................................................................B-4

Auxiliary Power.....................................................................................................................B-4

Simultaneous Welding and Auxiliary PowerLoads........................................................B-5

Extension Cord Recommendations...............................................................................B-5

Accessories.....................................................................................................Section C

General Options / Accessories..............................................................................C-1

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

Kolhler Engine Maintenance Schedule..................................................................D-1

Engine Oil Change ................................................................................................D-1

Routine and Periodic Engine Maintenance ...........................................................D-2

Oil....................................................................................................................D-2

Oil Filter...........................................................................................................D-2

Air Cleaner......................................................................................................D-2

Air Pre-Cleaner...............................................................................................D-2

Air Filter Paper Element..................................................................................D-3

Spark Plug ......................................................................................................D-3

Fuel Filter........................................................................................................D-3

Engine Adjustment..........................................................................................D-3

Battery Maintenance.......................................................................................D-4

Option Spark Arrestor .....................................................................................D-4

vii

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

A-1

INSTALLATION

RANGER 200

A-1

TECHNICAL SPECIFICATIONS - Ranger 200 (K1724-1)

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 15 HP @ (426 cc) (Group 58; 435 45.4 L

3600 RPM High Idle 3700 cold crank amps)

Bore x Stroke Battery Charger Oil: 2.0 Qts.

15 A. regulated 1.9 L

Full Load 3500 2.55” x 2.64”

(90 mm x 67mm) (Push Button Start)

INPUT - GASOLINE ENGINE

RATED OUTPUT - WELDER

HEIGHT WIDTH DEPTH WEIGHT

30.00 in. 21.50 in. 42.25 in. 409 lbs.

762.0 mm 546.0 mm 1073.0 mm 186 kg.

LUBRICATION VALVE LIFTERS FUEL SYSTEM GOVERNOR

Full Pressure Hydraulic Mechanical Fuel Pump Mechanical Governor
with Full Filter 5% Regulation

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Duel Element Automatic Idler Low noise Muffler: Top outlet Shutdown on low oil

can be rotated. Made from pressure.
long life, aluminized steel.

ENGINE WARRANTY: 2 year unlimited hours (See engine manufacturer warranty for details.)

OUTPUT - GENERATOR

Welding Output Volts at Rated Amps Duty Cycle Max. OCV @ 3700 RPM

CC DC Constant Current 210 amps

25 volts 100% 80 volts RMS

CC Output Range 40 to 210 amps

Auxiliary Power

1

6,000 Watts, 60 Hz

120/240 Volts

100 % Duty Cycle

PHYSICAL DIMENSIONS

ENGINE COMPONENTS

1. 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.

Cooling System:

Air-Cooled

A-2

INSTALLATION

A-2

INSTALLATION INSTRUCTIONS

SAFETY PRECAUTIONS
Only qualified personnel should install,
use, or service this equipment.

LOCATION AND VENTILATION

Whenever you use the RANGER 200, be sure that
clean cooling air can flow through the machine’s air
inlets and to avoid restricting the air outlets. 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 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.

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.

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

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.

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

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or
vent exhaust outside.

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

MOVING PARTS can injure.

• Do 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 200 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 10W30 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 200 machines CANNOT be stacked.

TILTING

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 gasoline 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 200

A-3

INSTALLATION

RANGER 200

A-3

HIGH ALTITUDE OPERATION

It may be necessary to de-rate the welder output at
higher altitudes. De-rate the welder output 3.5% for
every 1000 ft. (305m) above 5000 ft. (150 m). Some
engine adjustment may be required above 5,000 ft.
(1,525 m).

HIGH TEMPERATURE OPERATION

At temperatures above 30°C, output de-rating is nec­essary. For maximum output current ratings, de-rate
the welder output 5% for every 10°C above 30°C.

LIFTING

The RANGER 200 weighs approximately 490lbs / 222
kg. A lift bail is mounted to the machine frame 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.

The recommended trailer for use with this equipment
for in-plant and yard towing by a vehicle

(1)

is Lincoln’s
K957-1. If the user adapts a non-Lincoln undercarriage,
he must assume responsibility that the method of
attachment and usage does not result in a safety haz­ard nor damage the welding equipment. Some of the
factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln equip-

ment and likely additional attachments.

2. Proper support of, and attachment to, the base of

the welding equipment so there will be no undue
stress to the framework.

3. Proper placement of the equipment on the trailer to

insure stability side to side and front to back when
being moved and when standing by itself while
being operated or serviced.

WARNING

4. Typical conditions of use, i.e., travel speed; rough­ness of surface on which the trailer will be operat­ed; environmental conditions; likely maintenance.

5. Conformance with federal, state and local laws.

(1)

(1)

Consult applicable federal, state and local laws regarding
specific requirements for use on public highways.

PRE-OPERATION ENGINE SERVICE

READ and UNDERSTAND the engine operating and

maintenance instructions supplied with this machine.

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

• 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.

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

OIL

The RANGER 200 is shipped with the engine filled
with SAE 10W-30 oil. CHECK THE OIL LEVEL
BEFORE YOU START THE ENGINE. Check the oil
level every four hours of running time during the first
25 running hours. Refer to the engine Operator’s
Manual for specific oil recommendations and break-in
information. The oil change interval is dependent on
the quality of the oil and the operating environment.

For more information on oil viscosity and service con­ditions, see the MAINTENANCE section of this manu­al and the engine Operator’s Manual.

WARNING

CAUTION

A-4

INSTALLATION

A-4
FUEL

USE GASOLINE FUEL ONLY
Fill the fuel tank with clean fresh fuel only. Do not fill
to the top of the filler neck to allow room for expan­sion.

The RANGER 200 has a 12 gallon (45.4 liter) fuel
tank with a top fill and fuel gauge mounted on the con­trol panel. See the OPERATION and MAINTENANCE
sections of this manual for more details about fuel.
NOTE: The fuel tank is mounted below the engine so
a fuel shutoff valve is not required.

ENGINE COOLING SYSTEM

Air to cool the engine is drawn in a lower set of lou­vers on the case back. It is important that the intake
air is not restricted. Allow a minimum clearance of 2
feet (0.6m) from the case back to a vertical surface.

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

BATTERY CONNECTIONS

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.

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

WARNING

IMPORTANT: To prevent ELECTRICAL DAMAGE

WHEN:

a) Installing new batteries.
b) Using a booster.

Use correct polarity — Negative Ground.
The RANGER 200 is shipped with the negative bat-

tery cable disconnected. Make certain that the RUN­STOP switch is in the STOP position. Remove the two
screws from the rear battery tray using a screwdriver
or a 3/8” socket. Attach the negative battery cable to
the negative battery terminal and tighten using 1/2”
socket wrench.

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 OUTLET PIPE

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

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

The RANGER 200 is shipped with a muffler outlet
pipe. Using the clamp provided secure the outlet pipe
to the outlet tube with the pipe positioned such that it
will direct the exhuast in the desired direction. Tighten
using a 9/16” socket or wrench.

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 muffler (like the ones included with the
RANGER 200 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 (S24647) is available for your
RANGER 200. See the ACCESSORIES section of
this manual for more information.

An incorrect spark arrester may lead to damage to the
engine or reduce performance.

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

CAUTION

CAUTION

RANGER 200

A-5

INSTALLATION

RANGER 200

A-5

ELECTRICAL CONNECTIONS

MACHINE GROUNDING

Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.)

To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:

a) Be grounded to the frame of the welder using a

grounded type plug.

b) Be double insulated.

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

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

When this welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame
of the vehicle. When this engine driven welder is con­nected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
ground. See further connection instructions in the
section entitled "Standby Power Connections" as well
as the article on grounding in the latest U.S. National
Electrical Code and the local code.

In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into
the ground for at least ten feet and having no insulat­ed joints, or to the metal framework of a building
which has been effectively grounded. The U.S.
National Electrical Code lists a number of alternate
means of grounding electrical equipment. A machine
grounding stud marked with the symbol
is provided on the front of the welder.

WELDING OUTPUT CABLES

With the engine off connect the electrode and work
cables to the output studs. The welding process dic­tates the polarity of the electrode cable. These con­nections should be checked periodically and tightened
with a 3/4" wrench.

WARNING

Table A.1

CABLE INSTALLATION

Install the welding cables to your RANGER 200 as fol­lows. See Figure B.1 for location of parts.

1. The gasoline 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 output terminals. The terminals are identi­fied on the case front.

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.

• Loose connections will cause the output terminals to

overheat. The terminals may eventually melt.

• Do not cross the welding cables at the output termi-

nal connection. Keep the cables isolated and sepa­rate from one another.

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

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

Cable Length

0-100Ft. (0-30meters)

100-200 Ft. (30-46m meters)
200-250 Ft. (30-46 meters)

Cable Size for

210 Amps

100% Duty Cycle

2 AWG

1 AWG

1/0 AWG

CAUTION

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.

A-6

INSTALLATION

RANGER 200

A-6
AUXILIARY POWER RECEPTACLES &

PLUGS

The auxiliary power of the RANGER 200 consists of
two 20 Amp-120 VAC (5-20R) duplex receptacles and
one 50 Amp 120/240 VAC (14-50R) receptacle. The
240 VAC receptacle can be split for single phase 120
VAC operation.

The auxiliary power capacity is 6,000 watts of 60 Hz,
single phase power. The auxiliary power capacity rat­ing in watts is equivalent to volt-amperes at unity
power factor. The max permissible current of the 240
VAC output is 25 Amps. The 240 VAC output can be
split to provide two separate 120 VAC outputs with a
max permissible current of 25 Amps per output to two
separate 120 VAC branch circuits (these circuits can­not be paralleled). Output voltage is within ± 10% at
all loads up to rated capacity.

The 120 V auxiliary power receptacles 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.

STANDBY POWER CONNECTIONS

The RANGER 200 is suitable for temporary, standby
or emergency power using the engine manufacturer’s
recommended maintenance schedule.

The RANGER 200 can be permanently installed as a
standby power unit for 240 VAC, 3 wire, single phase,
25 amp service. Connections must be made by a
licensed electrician who can determine how the
120/240 VAC power can be adapted to the particular
installation and comply with all applicable electrical
codes.

PREMISES WIRING

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.

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

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 necessary steps to assure that the load is lim­ited to the capacity of the RANGER 200 by
installing a 25 amp, 240 VAC double pole circuit
breaker. Maximum rated load for each leg of the
240 VAC auxiliary is 25 amperes. Loading above
the rated output will reduce output voltage below
the allowable - 10% of rated voltage which may
damage appliances or other motor-driven equip­ment and may result in overheating of the RANGER
200 engine and/or alternator windings.

3. Install a 50 amp 120/240 volt plug (NEMA type 14-

50) to the double pole circuit breaker using No. 6 or
larger, 4 conductor cable of the desired length.
(The 50 amp 120/240 volt plug is available in the
optional K802R power plug kit.

4. Plug this cable in to the 50 amp 120/240 volt recep­tacle on the RANGER 200 case front.

WARNING

A-7

INSTALLATION

RANGER 200

A-7

Connection of Ranger 200 to premises wiring
must be done by a licensed electrician and must
comply with 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

NEUTRAL
BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

N

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

240 VOLT

GROUNDED CONDUCTOR

25AMP

240 VOLT

DOUBLE

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 200 TO PREMISES WIRING

WARNING

B-1

OPERATION

RANGER 200

B-1

GENERAL DESCRIPTION

The Ranger 200 is a gasoline engine powered DC
stick welding power source and 120/240 volt AC
power generator. The engine drives a generator that
supplies three phase power for the DC welding circuit
and single phase power for the AC auxiliary outlets.
The DC welding control system uses state of the art
Chopper Technology (CT tm) for superior welding
peformance.

DESIGN FEATURES

FOR AUXILIARY POWER:

Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
regardless of the welding control settings providing no
welding current is being drawn.

The auxiliary power of the RANGER 200 consists of
two 20 Amp-120 VAC (5-20R) duplex receptacles and
one 50 Amp 120/240 VAC (14-50R) receptacle. The
240 VAC receptacle can be split for single phase 120
VAC operation.

RECOMMENDED APPLICATIONS

PROCESSES:

Excellent DC stick welding (GMAW). The Ranger 200
can handle up to 3/16 dia. 6010 and 7018 elec­trodes. Can also be used for limited scratch start TIG
welding.

EQUIPMENT:

K710 Accessory Kit which includes:

Electrode holder and cable
Ground clamp and cable
Headshield

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door
closed and the side panels in place.

Read and understand all Safety Precautions before
operating this machine. Always follow these and any
other safety procedures included in this manual and in
the Engine Owner’s Manual.

Only qualified personnel should install, use, or service
this equipment.

CONTROLS AND SETTINGS

All generator/welder controls are located on the
Output Control Panel of the machine case front. See
figure on page B-2 and the explanations that follow.

B-2

OPERATION

B-2

RANGER 200

WELDING CONTROLS

1. OUTPUT CONTROL: The OUTPUT dial pro-

vides continuous control of the welding current.

2.THERMAL SHUTDOWN INDICATOR
LIGHT:Indicates that the welding output is shut off

because of blocked airflow or the welding current
exceeded the rating of the machine.

3.WELD OUTPUT TERMINALS WITH
FLANGE NUT:Provides a connection point for the

electrode and work cables.

4. GROUND STUD: Provides a connection point

for connecting the machine case to earth ground for
the safest grounding procedure.

ENGINE CONTROLS

5. RUN/STOP SWITCH:RUN position energizes

the engine prior to starting. STOP position stops the

1

2

3

4

5

6

7

8

10

9

engine. The oil pressure interlock switch prevents
battery drain if the switch is left in the RUN position
and the engine is not operating.

6. CHOKE: When pulled out, it closes the choke

valve on the engine carburetor for quick starting.

7. START: PUSH BUTTON - Energizes the starter

motor to crank the engine.

8. IDLER: SWITCH- Has two positions as follows:

1) In the HIGH position, the engine runs at the high

idle speed controlled by the engine governor.

2) In the AUTO position, the idler operates as fol-

lows:
A. When switched from HIGH to AUTO or after start-

ing the engine, the engine will operate at full speed
for approximately 12 seconds and then go to low
idle speed.

DO NOT FILL THE TANK TO THE POINT OF OVER-

FLOW.

3. Replace the fuel tank cap and tighten securely.

4. See Engine Owner’s Manual for specific fuel rec­ommendations.

STARTING THE ENGINE

1. Remove all plugs connected to the AC power

receptacles.

2. Set

IDLER switch to AUTO.

3. Set the RUN/STOP switch to RUN.

4. Pull the choke to the full out position.

5. Press and hold the engine

START button until the

engine starts.

6. Release the engine START button when the

engine starts.

7. Push the choke back in.

8. The engine will run at high idle speed for approxi-

mately 12 seconds and then go to low idle speed.
Allow the engine to warm up at low idle for several
minutes before applying a load and/or switching to
high idle. Allow a longer warm up time in cold
weather.

Operating the starter motor for more than 5 seconds
can damage the motor. If the engine fails to start,
release the switch and wait 10 seconds before opera-

tion the starter again. Do

NOT push the START

button while the engine is running because this can
damage the ring gear and/or the starter motor.

NOTE: When starting a Ranger 200 for the first

time, or after and extended period of time of not oper­ating, it will take longer than normal because the fuel
pump has to fill the fuel line and carburetor.

STOPPING THE ENGINE

1. Remove all welding and auxiliary power loads and

allow the engine to run at low idle speed for a few
minutes to cool the engine.

2. Stop the engine by placing the

RUN/STOP in the

STOPposition.

NOTE: A fuel shut off valve is not required on the
Ranger 200 because the fuel tank is mounted below
the engine.

CAUTION

B-3

OPERATION

B-3

ENGINE CONTROLS (CONTINUED)

B. When the electrode touches the work or power is

drawn for lights or tools (approximately 100 Watts
minimum) the engine accelerates and operates at
full speed.

C. When welding ceases or the AC power load is

turned off, a fixed time delay of approximately 12
seconds starts. If the welding or AC power load is
not restarted before the end of the time delay, the
idler reduces the engine speed to low idle speed.

D. The engine will automatically return to high idle

speed when there is welding load or AC power load
reapplied.

9. ENGINE ALTERNATOR TROUBLE
LIGHT: The yellow engine alternator light is off when

batterycharging system is functioning normally. If light
turns on, the alternator or the voltage regulator may
not be operating correctly. The light may also come
on due to the battery not holding a charge. It is nor­mal for the light to come on while starting the engine.

10. ENGINE HOUR METER: Displays the total

time that the engine has been running. This meter is
useful for scheduling prescribed maintenance.

ENGINE OPERATION

BEFORE STARTING THE ENGINE:

1. Be sure the machine is on a level surface.

2. Open top engine door and remove the engine oil
dipstick and wipe it with a clean cloth. Reinsert the
dipstick and check the level on the dipstick.

3. Add oil (if necessary) to bring the level up to the full
mark. Do not overfill. Close engine door.

4. See Engine Owner’s Manual for specific oil recom-

mendations.

Check and fill the engine fuel tank:

GASOLINE fuel can cause fire
or explosion.

• Stop engine when fueling.

• Do not smoke when fueling.

• Do not overfill tank.

• Keep sparks and flame away from tank.

1. Remove the fuel tank cap.

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.)

RANGER 200

WARNING

Stick Welding

The RANGER 200 can be used with a broad range of
DC stick electrodes.

TIG Welding

The RANGER 200 can be used for limited DC
Tungsten Inert Gas (TIG) welding applications using
the scratch start procedure. Start the arc while the
engine is running at low idle. TIG welding is normally
done with electrode negitive.

ARC GOUGING

Set the CONTROL knob to adjust output current to the
desired level for the gouging electrode being used
according to the ratings in the following table.

Electrode Diameter

Current Range (DC, electrode

positive)

1/8" 30-60 Amps
5/32" 90-150 Amps
3/16" 150-200 Amps

AUXILIARY POWER

Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
regardless of the welding control settings providing no
welding current is being drawn.

The auxiliary power of the RANGER 200 consists of
two 20 Amp-120 VAC (5-20R) duplex receptacles and
one 50 Amp 120/240 VAC (14-50R) receptacle. The
240 VAC receptacle can be split for single phase 120
VAC operation.

The auxiliary power capacity is 6,000 watts of 60 Hz,
single phase power. The auxiliary power capacity rat­ing in watts is equivalent to volt-amperes at unity
power factor. The max permissible current of the 240
VAC output is 25 Amps. The 240 VAC output can be
split to provide two separate 120 VAC outputs with a
max permissible current of 25 Amps per output to two
separate 120 VAC branch circuits (these circuits can­not be paralleled). Output voltage is within ± 10% at
all loads up to rated capacity.

The 120 V auxiliary power receptacles 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 240 V receptacle has two circuits, each of
which measure 120 V toneutral but are of opposite
polarities and cannot be paralleled.

B-4

OPERATION

B-4

TABLE B.1

TYPICAL RANGER 200 FUEL CONSUMPTION

WELDING OPERATION

RANGER 200

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.

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

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.

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

FUMES AND GASES can be
dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to
remove fumes from breathing zone.

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

MOVING PARTS can injure.

• Do not operate with doors open or
guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

WELDING SPARKS can cause fire or
explosion.

• Keep flammable material away.

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

ARC RAYS can burn.

• Wear eye, ear and body protection.

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

See additional warning information

throughout this operator’s manual.

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

WARNING

KOHLER CH 15

Low Idle - No Load
2500 RPM
High Idle - No Load
3700 RPM
DC CC Weld Output
210 Amps @ 25 Volts
Auxiliary Power,
6,000 VA

15 HP@3600

RPM GAL./HR

(LITERS/HR.)

.25 gallons/hour

(.95 liters/hour)

.52 gallons/hour

(2.0 liters/hour)

1.1 gallons/hour
(4.1 liters/hour)

1.0 gallons/hour
(3.9 liters/hour)

RUNNING

TIME 12 GAL.

(HOURS)

48
23
11
12

B-5

OPERATION

B-5

RANGER 200

Welding

Output Range

Setting

0

50
100
150
210

Permissibl Power Watts

(Unity Power Factor)

6000
4500
3000
1500

0

Permissible

Current in

@120 VAC *

40*

38*
25

12.5
0

Auxiliary
Amps

@ 240 VAC

25

18.8

12.5

6.3
0

* Each duplex receptacle is limited to 20 amps.
** Not to exceed 25 A per 120 VAC branch circuit when splitting the 240 VAC output.

Ranger 200 Simultaneous Welding and Power Loads

Ranger 200 Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

Current

(Amps)

15
20
15
20
25

Voltag
eVolts

120
120
240
240
240

Load

(Watts)

1800
2400
3600
4800
6000

30
60

(9)

(18)

40
30
75
60

(12)

(9)
(23)
(18)

75

50
150
100

90

(23)
(15)
(46)
(30)
(27)

125

88
225
175
150

(38)
(27)
(69)
(53)
(46)

175
138
350
275
225

(53)
(42)

(107)

(84)
(69)

300
225
600
450
250

(91)

(69)
(183)
(137)

(76)

Maximum Allowable Cord Length in ft. (m) for Conductor Size

Conductor size is based on manimum 2.0% voltage drop.

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

Simultaneous Welding and Auxiliary Power
Loads

The previous auxiliary power ratings are with no weld­ing load. Simultaneous welding and power loads are
specified in the following table. The permissible cur­rents shown assume that current is being drawn from
either the 120 VAC or 240 VAC supply (not both at the
same time).

C-1

ACCESSORIES

C-1

GENERAL OPTIONS /
ACCESSORIES

K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR
SMALL WELDERS

For road, off-road and in-plant and yard towing. (For
highway use, consult applicable federal, state and
local laws regarding requirements for brakes, lights,
fenders, etc.).

K1737-1 FOUR WHEEL ALL-TERRAIN
UNDERCARRIAGE (For moving by hand)

K1770.-1 UNDERCARRIAGE (FACTORY)

For moving by hand on a smooth surface. One or two
gas cylinders can be mounted on the rear of the
undercarriage with the installation of K1745-1 Cylinder
Holder(s).

K1739-1 CABLE CARRIER KIT

For use on K1737-1 and K1770-1 Undercarriages.

K1745-1 SINGLE GAS CYLINDER HOLDER

For use on K1770-1 Undercarriage. One or two may
be installed on an undercarriage.

K1788-1 ROLL CAGE

Gives added damage protection.

K886-2 CANVAS COVER

Protects Machine when not in use.

S24647 SPARK ARRESTER

Mounts inside exhaust pipe.

K1690-1 GFCI RECEPTACLE KIT

Includes one UL approved 120V ground fault circuit
interrupter duplex type receptacle with cover and
installation instructions. Replaces the factory installed
120V duplex receptacle. Each receptacle of the GFCI
Duplex is rated at 20 Amps, the maximum total cur­rent from the GFCI Duplex is limited to the 20 Amps.
Two kits are required.

K710 ACCESSORY KIT

Accessory set includes 30 f t. (9.1 meters) 3 AWG
electrode cable, 25 ft. (7.6 meters) 3 AWG work cable,
headshield with No. 12 filter, GC300 work clamp and
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.

K802-R POWER PLUG KIT

Provides four 120 volt plugs rated at 15 amps each
and one dual voltage, full KVA plug rated at 120/240
volts, 50 amps.

T12153-9 50 AMP, 120/240 V POWER PLUG

RANGER 200

D-1

MAINTENANCE

D-1

KOHLER ENGINE MAINTENANCE
SCHEDULE

TABLE D.1

(1) Service more frequently when used in dusty areas and/or at high ambient

temperatures.

Rerfer to your Operators Manual for periodic
maintenance.

Engine Oil Change

Drain the oil while the engine is warm to assure rapid
and complete draining.

1.Remove the oil filler cap and dipstick. Remove the
yellow cap from the oil drain valve and attach the
flexible drain tube supplied with the machine. Push
in and twist the drain valve counterclockwise. Pull
the valve out and drain the oil into a suitable con­tainer.

2. Close the drain valve by pushing in and twisting

clockwise. Replace the yellow cap.

3. Refill to the upper limit mark on the dipstick with the

recommended oil. Tighten the oil filler cap securely.

RANGER 200

SAFETY PRECAUTIONS

• Have qualified personnel do all maintenance
and troubleshooting work.

• Turn the engine off before working inside the
machine or servicing the engine.

• Remove guards only when necessary to
perform maintenance and replace them when
the maintenance requiring their removal is
complete. If guards are missing from the
machine, obtain replacements from a Lincoln
Distributor. (See Operating Manual Parts List.)

Read the Safety Precautions in the front of this
manual and in the Engine Owner’s Manual before
working on this machine.

Keep all equipment safety guards, covers, and
devices in position and in good repair. Keep hands,
hair, clothing, and tools away from the gears, fans,
and all other moving parts when starting, operating, or
repairing the equipment.

Routine Maintenance

At the end of each day’s use, refill the fuel tank to
minimize moisture condensation in the tank. Running
out of fuel tends to draw dirt into the fuel system.
Also, check the crankcase oil level and add oil if
indicated.

KOHLER ENGINE MAINTENANCE
COMPONENTS

TABLE D.2

WARNING

ITEM

MAKE AND PART NUMBER

Oil Filter Kohler 5205002
Air Filter Element Kohler 4708301, Fram CA6605
Air Filter Pre-Cleaner Kohler 5208301
Fuel Filter Kohler 2505002, Fram G1
Spark Plug Champion RC12YC (.040” Gap)
Battery BCI Group 58 (435)

FREQUENCY

Daily or Before
Starting Engine

Every 25 Hours
Every 100 Hours

Every 100 Hours
Every 100 Hours

Every 100 Hours
Every 200 Hours
Every 200 Hours
Every 2 Years

MAINTENANCE REQUIRED

• Fill fuel tank.

• Check oil level.

• Check air cleaner for dirty, loose,
or damaged parts.

• Check air intake and cooling
areas, clean as necessary.

• Service air pre-cleaner..

• Change engine oil.

(1)

• Replace fuel filter element.

• Clean or replace air filter ele-

ment.

(1)

• Spark Plug Arrester (Optional)

• Replace oil filter.

(1)

• Check spark plug and gap

• Check fuel lines and clamps.

D-2

MAINTENANCE

D-2

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. (Torque 10 ft. lbs., (13.6 N m)

5. Refill the crankcase with the specified amount of
the recommended oil. Reinstall the oil filler cap.

6. Start the engine and check for oil filter leaks.

7. Stop the engine, and check the oil level. If neces­sary, add oil to the upper limit mark on the dipstick.

Air Cleaner Service

A dirty air cleaner will restrict air flow to the carbure­tor. To prevent carburetor malfunction, service the air
cleaner regularly. Service more frequently when
operating the engine in extremely dusty areas.

Never use gasoline or low flash point solvents for
cleaning the air cleaner element. A fire or explosion
could result.

Never run the engine without the air cleaner. Rapid
engine wear will result from contaminants, such as
dust and dirt being drawn into the engine.

Kohler Engine

Air Pre-cleaner Service

1. Loosen the cover retaining knob and remove the
cover.

2. Remove the pre-cleaner from the paper element.

3. Wash the pre-cleaner in warm water with detergent.
Rinse the pre-cleaner thoroughly until all traces of
detergent are eliminated. Squeeze out excess
water (do not wring). Allow the pre-cleaner to air
dry.

4. Saturate the pre-cleaner with new engine oil.
Squeeze out all excess oil.

5. Reinstall the pre-cleaner over the paper element.

6. Reinstall the air cleaner cover. Secure cover with
the cover retaining knob.

RANGER 200

ROUTINE AND PERIODIC ENGINE
MAINTENANCE

To prevent the engine from accidentally starting, dis­connect the negative battery cable before servicing
the engine.

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

See Table D.1 for a summary of maintenance inter­vals for the items listed below. More frequent service
may be required, depending on your specific applica­tion and operating conditions. See the Kubota Engine
Operator's Manual for further information

OIL

Check the oil level before starting engine or daily. BE
SURE TO MAINTAIN THE OIL LEVEL. Change the

oil for the first time after 50 hours of operation. Then,
under normal operating conditions, change the oil as
specified in the maintenance schedule.

CHANGING THE OIL

Engine Oil Refill Capacities: (Kohler)

Without oil filter replacement: 1.70 US qt. (1.41 Imp
qt., 1.60 liter)
With oil filter replacement: 2.0 US qt. (1.66 Imp qt.,

1.90 liter)
Use 4-stroke motor oil that meets or exceeds the

requirements for API service classification SG or SH.
Always check the API SERVICE label on the oil con­tainer to be sure it includes the letters SG or SH.

Wash your hands with soap and water after handling
used oil.

Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you
take it in a sealed container to your local service sta­tion or recycling center for reclamation. Do not throw
it in the trash, pour it on the ground or down a drain.

OIL FILTER

Change the oil, while the engine is still warm, as fol­lows:

1. Drain the engine oil.

2. Remove the oil filter, and drain the oil into a suitable
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.

WARNING

Ambient Temperature Viscosity Grades

-5F

0

to 104F0(C-20 to 40 C) SAE 10W-30

CAUTION

WARNING

D-3

MAINTENANCE

D-3
AIR FILTER PAPER ELEMENT

1. Loosen the cover retaining knob and remove the
cover.

2. Remove the pre-cleaner from the paper element.

3. Remove the element cover nut, element cover, and
paper element.

4. Do not wash the paper element or use pressurized
air, as this will damage the element. Replace a
dirty, bent, or damaged element with a new ele­ment. Handle new elements carefully; do not use if
the sealing surfaces are bent or damaged.

5. When servicing the air cleaner, check the air clean­er base. Make sure it is secured and not bent or
damaged. Also check the element cover for dam­aged or improper fit. Replace all damaged air
cleaner components.

NOTE: Before air cleaner is reassembled make sure
rubber seal is in position around stud. Inspect, mak­ing sure it is not damaged and seals with the element
cover.

6. Reinstall the paper element, pre-cleaner, element
cover, element cover nut, and air cleaner cover.
Secure cover with the cover retaining knob.

SPARK PLUG

To ensure proper engine operation, the spark plug
must be properly gapped and free of deposits.

NOTE: Before removing spark plug, the muffler
becomes very hot during operation and remains hot
for a while after stopping the engine. Be careful not to
touch the muffler while it is hot.

1. Remove the spark plug cap.

2. Clean any dirt from around the spark plug base.

3. Use a plug wrench to remove the spark plug.

4. Visually inspect the spark plug. Discard them if the
insulator is cracked or chipped. Clean the spark
plug with a wire brush if it is to be reused.

5. Measure the plug gap with a feeler gauge. Correct
as necessary by bending the side electrode.

-Spark Plug Gap (.040 in.) (1.0 mm)

RANGER 200

6. Check that the spark plug washer is in good condi­tion and thread the spark plug in by hand to prevent
cross-threading.

7. After the spark plug is seated, tighten with a spark
plug wrench to compress the washer.

•If installing a new spark plug, tighten 1/2 turn after
the spark plug seats to compress the washer.

•If reinstalling a used spark plug, tighten 1/8 - 1/4 turn
after the spark plug seats to compress the washer.

•Spark Plug Torque: 20 ft. Lb. (27 N-m)

The spark plug must be securely tightened. An
improperly tightened spark plug can become very hot
and may cause engine damage.

Use only the recommended spark plug or equivalent.
A spark plug which has an improper heat range may
cause engine damage.

FUEL FILTER

1. Check the fuel filter for water accumulation or sedi­ment.

2. Replace the fuel filter if it is found with excessive
water accumulation or sediment.

ENGINE ADJUSTMENT

Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.

WARNING

CAUTION

WARNING

OVERSPEED IS HAZARDOUS

The maximum allowable high idle speed for
this machine is 3750 RPM, no load. Do NOT
tamper with governor components or setting
or make any other adjustments to increase
the maximum speed. Severe personal injury
and damage to the machine can result if
operated at speeds above maximum.

D-4

MAINTENANCE

D-4

RANGER 200

BATTERY MAINTENANCE

To access the battery, Remove the 3 screws from the
rear battery tray using a screwdriver or a 3/8" socket.
Slide the battery tray out only far enough to access
the battery terminals.

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.

CLEANING THE BATTERY

Keep the battery clean by wiping it with a damp cloth
when dirty. If the terminals appear corroded, discon­nect the battery cables and wash the terminals with an
ammonia solution or a solution of 1/4 pound (0.1113
kg) of baking soda and 1 quart (0.9461) of water. Be
sure the battery vent plugs (if equipped) are tight so
that none of the solution enters the cells.
After cleaning, flush the outside of the battery, the bat­tery compartment, and surrounding areas with clear
water. Coat the battery terminals lightly with petrole­um jelly or a non-conductive grease to retard corro­sion.

Keep the battery clean and dry. Moisture accumula­tion on the battery can lead to more rapid discharge
and early battery failure.

CHECKING THE ELECTROLYTE LEVEL

If battery cells are low, fill them to the neck of the filler
hole with distilled water and recharge. If one cell is
low, check for leaks.

CHARGING THE BATTERY

When you charge, jump, replace, or otherwise con­nect battery cables to the battery, be sure the polarity
is correct. Improper polarity can damage the charging
circuit. The RANGER 200 positive (+) battery terminal
has a red terminal cover.

If you need to charge the battery with an external
charger, disconnect the negative cable first, then the
positive cable before you attach the charger leads.
After the battery is charged, reconnect the positive
battery cable first and the negative cable last. Failure
to do so can result in damage to the internal charger
components.

Follow the instructions of the battery charger manu­facturer for proper charger settings and charging time.

OPTION SPARK ARRESTER

Clean every 100 hours.

WARNING

WARNING

MUFFLER MAY BE HOT

ALLOW ENGINE TO COOL BEFORE INSTALLING
THE SPARK ARRESTER!

DO NOT OPERATE ENGINE WHILE INSTALLING
THE SPARK ARRESTER!

D-5

MAINTENANCE

D-5

RANGER 200

Welder/Generator Maintenance

STORAGE: Store the RANGER 200 in clean, dry pro-

tected areas.

CLEANING: Blow out the generator and controls peri­odically with low pressure air. Do this at least once a
week in particularly dirty areas.

BRUSH REMOVAL AND REPLACEMENT: It’s nor­mal for the brushes and slip rings to wear and darken
slightly. Inspect the brushes when a generator over­haul is necessary.

Do not attempt to polish slip rings while the engine is
running.

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.

WARNING

E-1

TROUBLESHOOTING

E-1

RANGER 200

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 Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROB­LEMS (SYMPTOMS)”. This column
describes possible symptoms that the
machine may exhibit. Find the listing that
best describes the symptom that the
machine is exhibiting.
Symptoms are grouped into the following
categories: engine problems, function prob­lems and output problems.

Step 2. PERFORM EXTERNAL TESTS

The second column labeled "POSSIBLE
AREAS OF MISADJUSTMENT(S)" lists the
obvious external possibilities that may con­tribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted with­out removing the case wrap-around cover.

Step 3. RECOMMENDED COURSE OF
ACTION

This column provides a course of action for
the Possible Cause.If you do not under­stand or are unable to perform the
Recommended Course of Action safely,
contact you 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 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.

__________________________________________________________________________

WARNING

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output
terminals or internal wiring.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust
outside.

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

• Remove guards only when necessary and replace when work
requiring removal is complete.

• Only qualified personnel should install, use or service this
equipment.

E-2

TROUBLESHOOTING

E-2

RANGER 200

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 assistance before you proceed.

CAUTION

PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

Major Physical or Electrical Damage
is Evident.

Engine will not "crank".

Engine will "crank" but not start.

Engine shuts down shortly after
starting.

Battery does not stay charged.

1. Battery is low.

2. Loose battery cable connections.

3. Faulty engine starter motor.

4. “Battery Circuit” circuit breaker is
tripped.

1. Out of fuel.

2. Faulty fuel solenoid or faulty 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 charg­er modual.

1.I

f all recommended possible areas
of misadjustment have been
checked and the problem persists,

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 continues to trip, con

tact your local Lincoln AUTHO­RIZED FIELD SERVICE FACILI­TY.

1. Fill tank and bleed fuel system. See
MAINTENANCE section

2. Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.

1. Change oil and oil filter and fill to prop­er level. Start engine and look for
leaks.

2. Contact your Local Lincoln Authorized
Field Service Facility or authorized
engine service shop.

3. Contact your Local Lincoln Authorized
Field Service Facility or authorized
engine service shop.

1. Replace

2. Clean and tighten connections.

3. Consult authorized Engine Service
Shop.

E-3

TROUBLESHOOTING

E-3

RANGER 200

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 assistance before you proceed.

CAUTION

PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

Engine will not idle down to low
speed.

Engine will not go to high idle when
attempting to weld.

Engine will not go to high idle when
using auxiliary power.

Engine does not develop full power.

1. Idler switch in High idle position.

2. External load on welder or auxil­iary power.

3. Faulty PC board or idler solenoid.

1. Poor work lead connection to
work.

2. Faulty PC board. Low idle speed
set to 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 assistance.

1. Make sure work clamp is tightly con­nected to clean base metal.

2. Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.

1. Idler may not respond with less than a
100 watt load. Set idler to "High".

2. Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.

1. Replace.

2. Clean or replace.

3. Clean or replace.

4. Contact authorized Engine Service
Shop.

E-4

TROUBLESHOOTING

E-4

RANGER 200

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 assistance before you proceed.

CAUTION

PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

No welding power output. Thermal
shutdown light is on.

No welding power output. Thermal
shutdown light is NOT on.

Welder has output but no control.

No auxiliary power.

1. Airflow is blocked or restricted.

2. Welding current exceeding
machine rating.

1. Remove restriction and allow
machine to run until light goes off.

2. Use smaller electrode size or
slower wire feed speed. Allow
machine to run until light goes off.

3. Faulty PC board or welder alter-

nator.

1. Faulty control potentiometer or PC
board.

1. Open circuit breakers.

2. Faulty connections to auxiliary
receptacles.

3. GFCI tripped (if installed).

4. Faulty PC board or welder alterna­tor.

1. Remove restriction and allow
machine to run until light goes off.

2. Use smaller electrode size or
slower wire feed speed. Allow
machine to run until light goes off.

1. Make sure work clamp is tightly
connected to clean base metal.

2. Place switch in "Weld Terminals
On" position when welding without
control cable.

3. Contact your Local Lincoln
AUTHORIZED FIELD SERVICE
FACILITY for technical trou­bleshooting assistance.

1. Contact your Local Lincoln
AUTHORIZED FIELD SERVICE
FACILITY for technical trou­bleshooting assistance.

1. Reset breakers. If breakers keep
tripping, reduce power draw.

2. Check connections.

3. Clear any ground fault and reset
GFCI circuit by pressing "Reset"
button on the 120 V receptacle.

4. Contact your Local Lincoln
AUTHORIZED FIELD SERVICE
FACILITY for technical trou-

bleshooting assistance.

F-1

DIAGRAMS

F-1

S

PCB

1

D

1

THREE PHASE BRIDG

E

R

ECTIFIE

R

D

2 DIODEMODULE

66336363W10

R3

(

)

LEA

D

C

OLO

R COD

E:B

BLACK O

R GRAYR

R

E

D O

R PINKW

WHITE

G

GREEN (W/YELLOW STRIPE)

D4

GND HENGINEGROUNDFRAMEGROUN

D

POSPCBOAR

DTOHEATSINKCONN

.

R

F CHOKE

1276112123413151446586101698

1

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..

G3653

E-RW

RANGER 200 - WIRING DIAGRAM

J10

14 Pin

Ampenol

J9

Pinch/

J8

Hot Sta rt

P7- J7

Output

Contr ol

Meter

J4

J5

P6-J6

Meter

J2

J3

Machin e

J1

8

Progra ming

16

9

8

4

1

75

10K

76

77

O U TP U T C ON T. P O T

CC W

R1

W3

W ELD

STA TOR

W IND I NG S

W1

-

W4

789

456

J50

3 2 1

B1

B3

B2

W9

W8

Selecti on

6

Mode

Selecti on

5
1

3

W6

P50

23 2

23 3

TS 1

1 2 3

11

12

B7

20 0 A MP

MO DUL E

NE G

+

C1

252

253

25 W ATTS

13

250 OH M S

C H O K E

S HO W N T H R O U G H T O R O ID

L EA D S IN D IRE CTI O N

WR AP T W O T U R N S #3 & # 6

TE D PAIR
TWI

+

50 MV =4 00 AM PS

20 6B

SHU NT

204S

14

206S

6

10

4
1

1

5

5

W2

W3

23

T WISTED P AIR

987

654

25

H EA TS IN K

W7

14

260A

261A

260

26 1

20 8

208B

Shunt

10

6

4

2
1

1

206S

204S

L2

25 1

25 0

S4

ID L E R C O N T R OL

SHO W N IN

"AU TO PO SIT I ON "

P42-J42

P41-J41

10

4

3

5

1

2

5L

10 1A

13

14

11 5A

10 5A

11 6A

118A

97

42 VA C

FIE L D

WIN DING

GND -E
5

ST AT OR A UX . W IND IN G

4

4

3

3

3

1

1

1 2

2

2

77

75

76

6

1

12

11

PCB2 ANALOG POWER PC BOARD

20 0B

5L

IN SID E O F C AS E FR ON T

BO TT O M G ND . SCR E W ON

CENTE R BAFFLE

GND. SCR EW ON

GND-K

84

20 8

20 6B

P11 -J11

Arc F orce

6

3

9

5G

5H

GND-E

Thermal

16

6

4

4
1

8

1

3

25 0

23 0

23 2

23 3

23 1

20 8B

IDLE SO LENOID

210C

210C

20 9

5K

5F

-

M

5

5

1

S2

ST AR T

C B 7C32 5A

21 2

S1

21 2A

S1 SHO W N

IN "RU N"

PO SI TI ON

20 0

20 0A

80 0u f

15 0vdc

20 1

20 1A

W HI TE

D3

7

6

3

W HIT E

5C

5B

5A

INSIDE OF CASE FRONT

CENTER GND . S CR EW ON

FRAM E G N D.

G

ND

GR E EN

TO P GND . SCR E W ON

IN SI DE O F C AS E FR ON T

GND-L

FRAM E G N D.

6

4

12

3

1

6

8

P13-J13

P12-J12

21 0D

25 1

21 5

215

21 1

21 1A

BU TT ON

221

PO S.B RU SH

NE G. B RU SH

5H

3A

CB1

20 A

3D
BL AC K
W HIT E

J102

GND -G

GR E EN

G ND -J

POWER

PWM

Idler/

Sens e/

26 0A

5J

3A

20 A

5A

SI LV ER

GND -D

GR EE N

5

9

1

1

4

5F

11 8A

26 1A

25

10 1A

105A

1 15A

11 6A

23

TW ISTED PA IR

H OU R ME TE R

22 4B

21 0B

21 0A

RO T OR

5C

BL AC K

6B

CB2

BL AC K

6E

J101

G ND -C

PCB3 WEL D CONTROL PC BOARD

228

229

4

3

2

1

P34-J34

5G

BA T T E R Y

12 VO LT

+

P OS ITI VE BRU SH C ONN EC TE D

TO S LI P R IN G NE AR ES T

3

W HIT E

SI LVE R

+

5J

20 9

225

212A

221

22 4
21 0

TO T HE L AM IN AT ION

6B

BL AC K

3

6

6B

3A

35 A

35 A

CB5

CB6

3E

BL AC K

5B

W HIT E

BL AC K

6F

5C

115/2 3 0V

J100

3E

WHI TETE RM.

GREEN

P43-J43

16

9

8

1

21 1

22 9

22 8

21 0B

225

22 4B

20 0

5K

21 0D

PCB4 B ATTERY PC BOARD

230

231

4

3

1 2

P33-J33

PCB7 BA TTERY DISPLA Y

4

1 2 3

22 4

PCB6 TH ERMAL DISPLAY

GND J

GND P

207

FUEL

SHUTOFF

SOLEN OID

B-

AC
B

+

AC

KOHLER E NGINE COMPONEN TS

21 0

7

1

EL EC T RICA L SYMB O LS P ER E 15 37

C O N N E C TOR S VIEW ED FR OM I N S E R TIO N E N D

=

=

=

=

A LL CAS E FR ON T C OMP ON EN TS SH OW N V IEW ED F RO M RE AR .

987

654

P50

9 PIN

1 2 3

789

456

J50

3 2 1

9 PIN

VIE WE D FR O M LEAD S IDE OF R ECEPT ACLE

P ANE L RECE P T ACLE C AV ITY NU MBERIN G SEQ UENC E

F-2

DIMENSION PRINT RANGER 200

M19410

F-2

36.24

33.62

29.88

10.28 10.78

7.22

"B"

24.86

2.6

"A"

20.80

CENTER OF GRAVITY WITH OIL IN

ENGINE AND EMPTY FUEL TANK

42.10

17.50 19.50

41.20

TRUCK/UNDERCARRIAGE MOUNTING HOLES

F-3

NOTES

F-3

F-4

NOTES

RANGER 200

F-4

Now Available...12th Edition
The 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.

This printing will go fast so don’t delay. Place your
order now using the coupon below.

The hardbound book contains over 750 pages of welding
information, techniques and procedures. Much of this material
has never been included in any other book.

A must for all welders, supervisors, engineers and
designers. Many welding instructors will want to use the book
as a reference for all students by taking advantage of the low
quantity discount prices which include shipping by
4th class parcel post.

$15.00 postage paid U.S.A. Mainland

How To Read Shop Drawings

The book contains the latest information and application
data on the American Welding Society Standard Welding
Symbols. Detailed discussion tells how engineers and
draftsmen use the “short-cut” language of symbols to pass
on assembly and welding information to shop personnel.

Practical exercises and examples develop the reader’s

ability
to visualize mechanically drawn objects as they will appear
in their assembled form.

187 pages with more than 100 illustrations. Size 8-1/2” x

11”

Durable, cloth-covered board binding.

$4.50 postage paid U.S.A.

Mainland

New Lessons in Arc Welding

Lessons, simply written, cover manipulatory techniques;
machine and electrode characteristics; related subjects,
such as distortion; and supplemental information on arc
welding applications, speeds and costs. Practice materials,
exercises, questions and answers are suggested for each
lesson.

528 pages, well illustrated, 6” x 9” size, bound in simulated,
gold embossed leather.

$5.00 postage paid U.S.A.

Mainland

Need Welding Training?

The Lincoln Electric Company operates the oldest and
most respected Arc Welding School in the United States at its
corporate

headquarters in Cleveland, Ohio. Over 100,000 stu­dents have graduated. Tuition is low and the training is
“hands on”

For details write: Lincoln Welding School

22801 St. Clair Ave.
Cleveland, Ohio 44117-1199.

and ask for bulletin ED-80 or call 216-383-2259 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 for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:

$5.00 For order value up to $49.99
$10.00 For order value between $50.00 & $99.99
$15.00 For order value between $100.00 & $149.00

For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders)

CHECK ONE:

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Please Invoice (only if order is over $50.00)

Address: _______________________________________________

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USE THIS FORM TO ORDER:

Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199

BOOKS OR FREE INFORMATIVE CATALOGS Telephone: [phone] or, for fastest service, FAX this completed form to: 216-361-5901.

Lincoln Welding School Titles: Price Code Quantity Cost

(ED-80)

New Lessons in Arc Welding $5.00 L

Seminar Information Procedure Handbook “Twelfth Edition” $15.00 PH

(ED-45)

How to Read Shop Drawings $4.50 H

Educational Video Information Incentive Management $5.00 IM

(ED-93)

A New Approach to Industrial Economics $5.00 NA
James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
Foundation Book Information Welding Preheat Calculator $3.00 WC-8

(JFLF-515)

Pipe Welding Charts $4.50 ED-89

SUB TOTAL

Additional Shipping Costs if any

TOTAL COST

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WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch 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 moja­da.

● 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 Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

WARNING

AVISO DE

PRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für 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 öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● Do not operate with panel open or

guards off.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

• World's Leader in Welding and Cutting Products •