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: 216.481.8100 FAX: 216.486.1751 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
Loading...