RETURN TO MAIN INDEX
IM660
Ranger 200 January,2000
10646
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
� World's Leader in Welding and Cutting Products �
� 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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
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 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. 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.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating
products.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
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
a. Les circuits à l’électrode et à la piéce sont sous tension
la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours
endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue
de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans
age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains.
des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble
produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de
voir le code “Code for safety in welding and cutting� CSA
courant pour soudage semi-automatique, ces precautions
Standard W 117.2-1974.
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
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie
LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
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 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - Ranger 200 (K1724-1)
INPUT - GASOLINE ENGINE
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� Cooling System:
(90 mm x 67mm) (Push Button Start) Air-Cooled
RATED OUTPUT - WELDER
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
OUTPUT - GENERATOR
Auxiliary Power 1
6,000 Watts, 60 Hz
120/240 Volts
100 % Duty Cycle
PHYSICAL DIMENSIONS
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.
ENGINE COMPONENTS
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.)
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.
RANGER 200
A-2 A-2
INSTALLATION
Always operate the RANGER 200 with the case roof
INSTALLATION INSTRUCTIONS on and all machine components completely assem-
bled. This will protect you from the dangers of moving
parts, hot metal surfaces, and live electrical devices.
WARNING STORING
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s 1. Store the machine in a cool, dry place when it is not
manual supplied with your welder. It includes in use. Protect it from dust and dirt. Keep it where
important safety precautions, detailed engine
it can’t be accidentally damaged from construction
starting, operating and maintenance instructions,
activities, moving vehicles, and other hazards.
and parts lists.
------------------------------------------------------------------------
2. Drain the engine oil and refill with fresh 10W30 oil.
ELECTRIC SHOCK can kill.
� Do not touch electrically live parts or Run the engine for about five minutes to circulate oil
electrode with skin or wet clothing. to all the parts. See the MAINTENANCE section of
� Insulate yourself from work and this manual for details on changing oil.
ground
� Always wear dry insulating gloves.
3. Remove the battery, recharge it, and adjust the
------------------------------------------------------------------------
electrolyte level. Store the battery in a dry, dark
ENGINE EXHAUST can kill.
place.
� Use in open, well ventilated areas or
vent exhaust outside.
STACKING
------------------------------------------------------------------------
RANGER 200 machines CANNOT be stacked.
MOVING PARTS can injure.
� Do not operate with doors open or
guards off.
� Stop engine before servicing. TILTING
� Keep away from moving parts.
------------------------------------------------------------------------
Place the machine on a secure, level surface whenev-
er you use it or store it. Any surfaces you place it on
See additional warning information at
other than the ground must be firm, non-skid, and
front of this operator’s manual. structurally sound.
-----------------------------------------------------------
The gasoline engine is designed to run in a level posi-
tion for best performance. It can operate at an angle,
SAFETY PRECAUTIONS
but this should never be more than 15 degrees in any
Only qualified personnel should install,
direction. If you do operate it at a slight angle, be sure
use, or service this equipment.
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.
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 ven-
tilated 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.
RANGER 200
A-3 A-3
INSTALLATION
HIGH ALTITUDE OPERATION 4. Typical conditions of use, i.e., travel speed; rough-
ness of surface on which the trailer will be operat-
It may be necessary to de-rate the welder output at
ed; environmental conditions; likely maintenance.
higher altitudes. De-rate the welder output 3.5% for
every 1000 ft. (305m) above 5000 ft. (150 m). Some
5. Conformance with federal, state and local laws.(1)
engine adjustment may be required above 5,000 ft.
(1,525 m).
(1) Consult applicable federal, state and local laws regarding
specific requirements for use on public highways.
HIGH TEMPERATURE OPERATION
At temperatures above 30°C, output de-rating is nec-
essary. For maximum output current ratings, de-rate
the welder output 5% for every 10°C above 30°C.
PRE-OPERATION ENGINE SERVICE
LIFTING READ and UNDERSTAND the engine operating and
The RANGER 200 weighs approximately 490lbs / 222
CAUTION
kg. A lift bail is mounted to the machine frame and
should always be used when lifting the machine. maintenance instructions supplied with this machine.
------------------------------------------------------------------------
WARNING � Keep hands way from the engine muffler or HOT
WARNING
ADDITIONAL SAFETY
PRECAUTIONS
engine parts.
FALLING EQUIPMENT can cause
injury.
� Stop the engine when fueling.
Do not lift this machine using lift bale if it is
q
equipped with a heavy accessory such as trailer � Do not smoke when fueling.
or gas cylinder.
Lift only with equipment of adequate lifting
q � Do not overfill the fuel tank.
capacity.
� Wipe up spilled fuel and allow the fumes to clear
Be sure machine is stable when lifting.
q
before starting the engine.
� Keep sparks and flame away from the fuel tank.
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,
OIL
he must assume responsibility that the method of
attachment and usage does not result in a safety haz-
ard nor damage the welding equipment. Some of the The RANGER 200 is shipped with the engine filled
factors to be considered are as follows: with SAE 10W-30 oil. CHECK THE OIL LEVEL
BEFORE YOU START THE ENGINE. Check the oil
1. Design capacity of trailer vs. weight of Lincoln equip- level every four hours of running time during the first
ment and likely additional attachments. 25 running hours. Refer to the engine Operator’s
Manual for specific oil recommendations and break-in
2. Proper support of, and attachment to, the base of information. The oil change interval is dependent on
the welding equipment so there will be no undue the quality of the oil and the operating environment.
stress to the framework.
For more information on oil viscosity and service con-
3. Proper placement of the equipment on the trailer to ditions, see the MAINTENANCE section of this manu-
insure stability side to side and front to back when al and the engine Operator’s Manual.
being moved and when standing by itself while
being operated or serviced.
RANGER 200
A-4 A-4
INSTALLATION
FUEL IMPORTANT: To prevent ELECTRICAL DAMAGE
WHEN:
a) Installing new batteries.
USE GASOLINE FUEL ONLY b) Using a booster.
Fill the fuel tank with clean fresh fuel only. Do not fill
Use correct polarity � Negative Ground.
to the top of the filler neck to allow room for expan-
sion. The RANGER 200 is shipped with the negative bat-
tery cable disconnected. Make certain that the RUN-
The RANGER 200 has a 12 gallon (45.4 liter) fuel STOP switch is in the STOP position. Remove the two
tank with a top fill and fuel gauge mounted on the con- screws from the rear battery tray using a screwdriver
trol panel. See the OPERATION and MAINTENANCE or a 3/8� socket. Attach the negative battery cable to
sections of this manual for more details about fuel. the negative battery terminal and tighten using 1/2�
NOTE: The fuel tank is mounted below the engine so socket wrench.
a fuel shutoff valve is not required.
NOTE: This machine is furnished with a wet charged
ENGINE COOLING SYSTEM battery; if unused for several months, the battery may
Air to cool the engine is drawn in a lower set of lou- require a booster charge. Be sure to use the correct
vers on the case back. It is important that the intake polarity when charging the battery.
air is not restricted. Allow a minimum clearance of 2
feet (0.6m) from the case back to a vertical surface. MUFFLER OUTLET PIPE
CAUTION
WARNING Shut off the machine and allow the muffler to cool
before touching the muffler.
------------------------------------------------------------------------
------------------------------------------------------------------------
BATTERY CONNECTIONS The RANGER 200 is shipped with a muffler outlet
GASES FROM BATTERY can explode. pipe. Using the clamp provided secure the outlet pipe
to the outlet tube with the pipe positioned such that it
q Keep sparks, flame and cigarettes
will direct the exhuast in the desired direction. Tighten
away from battery.
using a 9/16� socket or wrench.
To prevent EXPLOSION when: SPARK ARRESTER
q INSTALLING A NEW BATTERY � disconnect
Gasoline engine mufflers may emit sparks when the
negative cable from old battery first and connect to
engine is running. Some federal, state, or local laws
new battery last.
require spark arresters in locations where unarrested
q CONNECTING A BATTERY CHARGER �
sparks could present a fire hazard.
remove battery from welder by disconnecting nega-
tive cable first, then positive cable and battery
Standard muffler (like the ones included with the
clamp. When reinstalling, connect
RANGER 200 do not act as spark arresters. When
negative cable last. Keep well ventilated.
local laws require it, a spark arrester must be installed
USING A BOOSTER � connect positive lead to
q on the machine and properly maintained. An optional
battery first then connect negative lead to negative spark arrester kit (S24647) is available for your
battery lead at engine foot. RANGER 200. See the ACCESSORIES section of
this manual for more information.
BATTERY ACID can burn eyes and
CAUTION
skin.
q Wear gloves and eye protection and
An incorrect spark arrester may lead to damage to the
be careful when working near battery.
engine or reduce performance.
q Follow instructions printed on battery.
------------------------------------------------------------------------
------------------------------------------------------------------------
RANGER 200
A-5 A-5
INSTALLATION
ELECTRICAL CONNECTIONS
MACHINE GROUNDING
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
Because this portable engine driven welder creates its
distance from the welder to the work and back to the
own power, it is not necessary to connect its frame to
welder. Cable diameters are increased for long cable
an earth ground, unless the machine is connected to
lengths to reduce voltage drops.
premises wiring (home, shop, etc.)
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power TOTAL COMBINED LENGTH OF
must: ELECTRODE AND WORK CABLES
Cable Size for
a) Be grounded to the frame of the welder using a
Cable Length 210 Amps
grounded type plug.
100% Duty Cycle
2 AWG
b) Be double insulated. 0-100Ft. (0-30meters)
WARNING 1 AWG
100-200 Ft. (30-46m meters)
1/0 AWG
Do not ground the machine to a pipe that carries 200-250 Ft. (30-46 meters)
explosive or combustible material.
------------------------------------------------------------------------
Table A.1
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 con- CABLE INSTALLATION
nected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth Install the welding cables to your RANGER 200 as fol-
ground. See further connection instructions in the lows. See Figure B.1 for location of parts.
section entitled "Standby Power Connections" as well
as the article on grounding in the latest U.S. National 1. The gasoline engine must be OFF to install welding
Electrical Code and the local code. cables.
In general, if the machine is to be grounded, it should 2. Remove the flanged nuts from the output terminals.
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into 3. Connect the electrode holder and work cables to
the ground for at least ten feet and having no insulat- the weld output terminals. The terminals are identi-
ed joints, or to the metal framework of a building fied on the case front.
which has been effectively grounded. The U.S.
National Electrical Code lists a number of alternate 4. Tighten the flanged nuts securely.
means of grounding electrical equipment. A machine
grounding stud marked with the symbol 5. Be certain that the metal piece you are welding (the
is provided on the front of the welder. “work�) is properly connected to the work clamp and
cable.
WELDING OUTPUT CABLES 6. Check and tighten the connections periodically.
� Loose connections will cause the output terminals to
With the engine off connect the electrode and work
overheat. The terminals may eventually melt.
cables to the output studs. The welding process dic-
tates the polarity of the electrode cable. These con-
CAUTION
nections should be checked periodically and tightened
with a 3/4" wrench.
� Do not cross the welding cables at the output termi-
nal connection. Keep the cables isolated and sepa-
rate from one another.
------------------------------------------------------------------------
RANGER 200
A-6 A-6
INSTALLATION
AUXILIARY POWER RECEPTACLES & PREMISES WIRING
PLUGS
WARNING
The auxiliary power of the RANGER 200 consists of
two 20 Amp-120 VAC (5-20R) duplex receptacles and
Only a licensed, certified, trained electrician should
one 50 Amp 120/240 VAC (14-50R) receptacle. The
install the machine to a premises or residential elec-
240 VAC receptacle can be split for single phase 120
trical system. Be certain that:
VAC operation.
� The installation complies with the National Electrical
The auxiliary power capacity is 6,000 watts of 60 Hz,
Code and all other applicable electrical codes.
single phase power. The auxiliary power capacity rat-
ing in watts is equivalent to volt-amperes at unity
� The premises is isolated and no feedbacking into
power factor. The max permissible current of the 240
the utility system can occur. Certain state and local
VAC output is 25 Amps. The 240 VAC output can be
laws require the premises to be isolated before the
split to provide two separate 120 VAC outputs with a
generator is linked to the premises. Check your
max permissible current of 25 Amps per output to two
state and local requirements.
separate 120 VAC branch circuits (these circuits can-
not be paralleled). Output voltage is within ± 10% at
� A double pole, double throw transfer switch in con-
all loads up to rated capacity.
junction with the properly rated double throw circuit
breaker is connected between the generator power
The 120 V auxiliary power receptacles should only be
and the utility meter.
used with three wire grounded type plugs or approved
------------------------------------------------------------------------
double insulated tools with two wire plugs. The cur-
The following information and the connection diagram,
rent rating of any plug used with the system must be
Figure A.1, can be used as a guide by the electrician
at least equal to the current capacity of the associated
for most applications to premises wiring.
receptacle.
1. Install a double pole, double throw switch between
STANDBY POWER CONNECTIONS
the power company meter and the premises dis-
connect. The switch rating must be the same as or
The RANGER 200 is suitable for temporary, standby
greater than the premises disconnect and service
or emergency power using the engine manufacturer’s
overcurrent protection.
recommended maintenance schedule.
2. Take necessary steps to assure that the load is lim-
The RANGER 200 can be permanently installed as a
ited to the capacity of the RANGER 200 by
standby power unit for 240 VAC, 3 wire, single phase,
installing a 25 amp, 240 VAC double pole circuit
25 amp service. Connections must be made by a
breaker. Maximum rated load for each leg of the
licensed electrician who can determine how the
240 VAC auxiliary is 25 amperes. Loading above
120/240 VAC power can be adapted to the particular
the rated output will reduce output voltage below
installation and comply with all applicable electrical
the allowable - 10% of rated voltage which may
codes.
damage appliances or other motor-driven equip-
ment 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 recep-
tacle on the RANGER 200 case front.
RANGER 200
A-7 A-7
INSTALLATION
Figure A.1
CONNECTION OF RANGER 200 TO PREMISES WIRING
240 VOLT
GROUNDED CONDUCTOR
POWER
240 Volt 120 VOLT
60 Hz.
COMPANY
3-Wire
120 VOLT
Service
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
25AMP
PROTECTION
240 VOLT
DOUBLE
POLE
50 AMP, 120/240 CIRCUIT
VOLT PLUG 240 VOLT BREAKER
NEMA TYPE 14-50
GND
N
50 AMP, 120/240 VOLT
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
RECEPTACLE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
WARNING
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.
RANGER 200
B-1 B-1
OPERATION
GENERAL DESCRIPTION CONTROLS AND SETTINGS
The Ranger 200 is a gasoline engine powered DC All generator/welder controls are located on the
stick welding power source and 120/240 volt AC Output Control Panel of the machine case front. See
power generator. The engine drives a generator that figure on page B-2 and the explanations that follow.
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 elec-
trodes. 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.
RANGER 200
B-2 B-2
OPERATION
1 10
9
8
7
2
6
5
3
4
WELDING CONTROLS engine. The oil pressure interlock switch prevents
battery drain if the switch is left in the RUN position
1. OUTPUT CONTROL: The OUTPUT dial pro-
and the engine is not operating.
vides continuous control of the welding current.
6. CHOKE: When pulled out, it closes the choke
2. THERMAL SHUTDOWN INDICATOR
valve on the engine carburetor for quick starting.
LIGHT: Indicates that the welding output is shut off
because of blocked airflow or the welding current
7. START: PUSH BUTTON - Energizes the starter
exceeded the rating of the machine.
motor to crank the engine.
3. WELD OUTPUT TERMINALS WITH 8. IDLER: SWITCH- Has two positions as follows:
FLANGE NUT: Provides a connection point for the
electrode and work cables.
1) In the HIGH position, the engine runs at the high
idle speed controlled by the engine governor.
4. GROUND STUD: Provides a connection point
for connecting the machine case to earth ground for 2) In the AUTO position, the idler operates as fol-
the safest grounding procedure.
lows:
ENGINE CONTROLS A. When switched from HIGH to AUTO or after start-
ing the engine, the engine will operate at full speed
5. RUN/STOP SWITCH: RUN position energizes
for approximately 12 seconds and then go to low
the engine prior to starting. STOP position stops the
idle speed.
RANGER 200
B-3 B-3
OPERATION
ENGINE CONTROLS (CONTINUED) DO NOT FILL THE TANK TO THE POINT OF OVER-
FLOW.
B. When the electrode touches the work or power is
3. Replace the fuel tank cap and tighten securely.
drawn for lights or tools (approximately 100 Watts
minimum) the engine accelerates and operates at
4. See Engine Owner’s Manual for specific fuel rec-
full speed.
ommendations.
C. When welding ceases or the AC power load is
turned off, a fixed time delay of approximately 12
STARTING THE ENGINE
seconds starts. If the welding or AC power load is
not restarted before the end of the time delay, the 1. Remove all plugs connected to the AC power
idler reduces the engine speed to low idle speed. receptacles.
D. The engine will automatically return to high idle 2. Set IDLER switch to AUTO.
speed when there is welding load or AC power load
reapplied. 3. Set the RUN/STOP switch to RUN.
9. ENGINE ALTERNATOR TROUBLE 4. Pull the choke to the full out position.
LIGHT: The yellow engine alternator light is off when
batterycharging system is functioning normally. If light START button until the
5. Press and hold the engine
turns on, the alternator or the voltage regulator may engine starts.
not be operating correctly. The light may also come
on due to the battery not holding a charge. It is nor- START button when the
6. Release the engine
mal for the light to come on while starting the engine.
engine starts.
10. ENGINE HOUR METER: Displays the total 7. Push the choke back in.
time that the engine has been running. This meter is
useful for scheduling prescribed maintenance. 8. The engine will run at high idle speed for approxi-
mately 12 seconds and then go to low idle speed.
ENGINE OPERATION Allow the engine to warm up at low idle for several
minutes before applying a load and/or switching to
BEFORE STARTING THE ENGINE:
high idle. Allow a longer warm up time in cold
1. Be sure the machine is on a level surface.
weather.
2. Open top engine door and remove the engine oil CAUTION
dipstick and wipe it with a clean cloth. Reinsert the
dipstick and check the level on the dipstick.
Operating the starter motor for more than 5 seconds
can damage the motor. If the engine fails to start,
3. Add oil (if necessary) to bring the level up to the full
release the switch and wait 10 seconds before opera-
mark. Do not overfill. Close engine door.
tion the starter again. Do NOT push the START
button while the engine is running because this can
4. See Engine Owner’s Manual for specific oil recom-
damage the ring gear and/or the starter motor.
mendations.
NOTE: When starting a Ranger 200 for the first
time, or after and extended period of time of not oper-
Check and fill the engine fuel tank:
ating, it will take longer than normal because the fuel
pump has to fill the fuel line and carburetor.
WARNING
GASOLINE fuel can cause fire
STOPPING THE ENGINE
or explosion.
1. Remove all welding and auxiliary power loads and
� Stop engine when fueling.
allow the engine to run at low idle speed for a few
� Do not smoke when fueling.
minutes to cool the engine.
� Do not overfill tank.
2. Stop the engine by placing the RUN/STOP in the
� Keep sparks and flame away from tank.
STOP position.
NOTE: A fuel shut off valve is not required on the
1. Remove the fuel tank cap.
Ranger 200 because the fuel tank is mounted below
the engine.
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
B-4 B-4
OPERATION
TABLE B.1 Stick Welding
The RANGER 200 can be used with a broad range of
TYPICAL RANGER 200 FUEL CONSUMPTION DC stick electrodes.
TIG Welding
RUNNING
KOHLER CH 15 15 HP@3600
The RANGER 200 can be used for limited DC
RPM GAL./HR TIME 12 GAL.
Tungsten Inert Gas (TIG) welding applications using
(HOURS)
(LITERS/HR.)
the scratch start procedure. Start the arc while the
Low Idle - No Load .25 gallons/hour
engine is running at low idle. TIG welding is normally
48
2500 RPM (.95 liters/hour)
done with electrode negitive.
High Idle - No Load .52 gallons/hour
ARC GOUGING
23
3700 RPM (2.0 liters/hour)
Set the CONTROL knob to adjust output current to the
DC CC Weld Output 1.1 gallons/hour
desired level for the gouging electrode being used
11
210 Amps @ 25 Volts (4.1 liters/hour)
according to the ratings in the following table.
Auxiliary Power, 1.0 gallons/hour
12
6,000 VA (3.9 liters/hour)
Electrode Diameter Current Range (DC, electrode
positive)
WELDING OPERATION
1/8" 30-60 Amps
WARNING
5/32" 90-150 Amps
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
3/16" 150-200 Amps
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
------------------------------------------------------------------------
AUXILIARY POWER
ELECTRIC SHOCK can kill.
Start the engine and set the IDLER control switch to
� Do not touch electrically live parts
or electrode with skin or wet the desired operating mode. Full power is available
clothing. regardless of the welding control settings providing no
� Insulate yourself from work and welding current is being drawn.
ground
� Always wear dry insulating gloves.
The auxiliary power of the RANGER 200 consists of
------------------------------------------------------------------------
two 20 Amp-120 VAC (5-20R) duplex receptacles and
FUMES AND GASES can be
one 50 Amp 120/240 VAC (14-50R) receptacle. The
dangerous.
� Keep your head out of fumes. 240 VAC receptacle can be split for single phase 120
� Use ventilation or exhaust to VAC operation.
remove fumes from breathing zone.
The auxiliary power capacity is 6,000 watts of 60 Hz,
------------------------------------------------------------------------
single phase power. The auxiliary power capacity rat-
MOVING PARTS can injure.
ing in watts is equivalent to volt-amperes at unity
� Do not operate with doors open or
power factor. The max permissible current of the 240
guards off.
� Stop engine before servicing. VAC output is 25 Amps. The 240 VAC output can be
� Keep away from moving parts. split to provide two separate 120 VAC outputs with a
------------------------------------------------------------------------ max permissible current of 25 Amps per output to two
WELDING SPARKS can cause fire or separate 120 VAC branch circuits (these circuits can-
explosion.
not be paralleled). Output voltage is within ± 10% at
� Keep flammable material away.
all loads up to rated capacity.
------------------------------------------------------------------------ The 120 V auxiliary power receptacles should only be
ARC RAYS can burn. used with three wire grounded type plugs or approved
� Wear eye, ear and body protection. double insulated tools with two wire plugs. The cur-
rent rating of any plug used with the system must be
at least equal to the current capacity of the associated
receptacle.
------------------------------------------------------------------------
See additional warning information
NOTE: The 240 V receptacle has two circuits, each of
throughout this operator’s manual.
which measure 120 V toneutral but are of opposite
----------------------------------------------------------- polarities and cannot be paralleled.
RANGER 200
B-5 B-5
OPERATION
Simultaneous Welding and Auxiliary Power
Loads
The previous auxiliary power ratings are with no weld-
ing load. Simultaneous welding and power loads are
specified in the following table. The permissible cur-
rents shown assume that current is being drawn from
either the 120 VAC or 240 VAC supply (not both at the
same time).
Ranger 200 Simultaneous Welding and Power Loads
Permissible Auxiliary
Permissibl Power Watts
Welding
Current in Amps
(Unity Power Factor)
Output Range
Setting
@120 VAC * @ 240 VAC
40* 25
6000
0
38* 18.8
4500
50
25 12.5
3000
100
12.5 6.3
1500
150
0 0
0
210
* 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 Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
Current Voltag Load
14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
(Amps) eVolts (Watts)
15 120 1800 30 (9) 40 (12) 75 (23) 125 (38) 175 (53) 300 (91)
20 120 2400 30 (9) 50 (15) 88 (27) 138 (42) 225 (69)
15 240 3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)
20 240 4800 60 (18) 100 (30) 175 (53) 275 (84) 450 (137)
25 240 6000 90 (27) 150 (46) 225 (69) 250 (76)
Conductor size is based on manimum 2.0% voltage drop.
RANGER 200
C-1 C-1
ACCESSORIES
GENERAL OPTIONS / K802-R POWER PLUG KIT
Provides four 120 volt plugs rated at 15 amps each
ACCESSORIES and one dual voltage, full KVA plug rated at 120/240
volts, 50 amps.
K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR
SMALL WELDERS T12153-9 50 AMP, 120/240 V POWER PLUG
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 cur-
rent 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.
RANGER 200
D-1 D-1
MAINTENANCE
KOHLER ENGINE MAINTENANCE
SAFETY PRECAUTIONS
SCHEDULE
WARNING
� Have qualified personnel do all maintenance
TABLE D.1
and troubleshooting work.
FREQUENCY MAINTENANCE REQUIRED
� Turn the engine off before working inside the
machine or servicing the engine. Daily or Before � Fill fuel tank.
� Remove guards only when necessary to Starting Engine � Check oil level.
perform maintenance and replace them when � Check air cleaner for dirty, loose,
the maintenance requiring their removal is or damaged parts.
complete. If guards are missing from the � Check air intake and cooling
machine, obtain replacements from a Lincoln areas, clean as necessary.
Distributor. (See Operating Manual Parts List.)
Read the Safety Precautions in the front of this Every 25 Hours � Service air pre-cleaner..
manual and in the Engine Owner’s Manual before
working on this machine. Every 100 Hours � Change engine oil. (1)
Every 100 Hours � Replace fuel filter element.
Keep all equipment safety guards, covers, and Every 100 Hours � Clean or replace air filter ele-
devices in position and in good repair. Keep hands, ment. (1)
hair, clothing, and tools away from the gears, fans, Every 100 Hours � Spark Plug Arrester (Optional)
and all other moving parts when starting, operating, or Every 200 Hours � Replace oil filter. (1)
repairing the equipment. Every 200 Hours � Check spark plug and gap
Every 2 Years � Check fuel lines and clamps.
Routine Maintenance
(1) Service more frequently when used in dusty areas and/or at high ambient
temperatures.
At the end of each day’s use, refill the fuel tank to
Rerfer to your Operators Manual for periodic
minimize moisture condensation in the tank. Running
maintenance.
out of fuel tends to draw dirt into the fuel system.
Also, check the crankcase oil level and add oil if
Engine Oil Change
indicated.
Drain the oil while the engine is warm to assure rapid
and complete draining.
KOHLER ENGINE MAINTENANCE
COMPONENTS 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
TABLE D.2
in and twist the drain valve counterclockwise. Pull
ITEM MAKE AND PART NUMBER
the valve out and drain the oil into a suitable con-
tainer.
Oil Filter Kohler 5205002
2. Close the drain valve by pushing in and twisting
Air Filter Element Kohler 4708301, Fram CA6605 clockwise. Replace the yellow cap.
Air Filter Pre-Cleaner Kohler 5208301 3. Refill to the upper limit mark on the dipstick with the
recommended oil. Tighten the oil filler cap securely.
Fuel Filter Kohler 2505002, Fram G1
Spark Plug Champion RC12YC (.040� Gap)
Battery BCI Group 58 (435)
RANGER 200
D-2 D-2
MAINTENANCE
4. Screw on the new oil filter by hand, until the gasket
ROUTINE AND PERIODIC ENGINE
contacts the filter mounting base, then use an oil fil-
MAINTENANCE ter socket tool to tighten the filter an additional 1/2
to 7/8 turn. (Torque 10 ft. lbs., (13.6 N m)
WARNING
5. Refill the crankcase with the specified amount of
To prevent the engine from accidentally starting, dis- the recommended oil. Reinstall the oil filler cap.
connect the negative battery cable before servicing
the engine. 6. Start the engine and check for oil filter leaks.
------------------------------------------------------------------------
See Table D.1 for a summary of maintenance inter- 7. Stop the engine, and check the oil level. If neces-
vals for the items listed below. More frequent service sary, add oil to the upper limit mark on the dipstick.
may be required, depending on your specific applica-
tion 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
Air Cleaner Service
oil for the first time after 50 hours of operation. Then,
A dirty air cleaner will restrict air flow to the carbure-
under normal operating conditions, change the oil as
tor. To prevent carburetor malfunction, service the air
specified in the maintenance schedule.
cleaner regularly. Service more frequently when
CHANGING THE OIL
operating the engine in extremely dusty areas.
Ambient Temperature Viscosity Grades
-5F 0 to 104F 0 (C-20 to 40 C) SAE 10W-30
WARNING
Engine Oil Refill Capacities: (Kohler) Never use gasoline or low flash point solvents for
Without oil filter replacement: 1.70 US qt. (1.41 Imp cleaning the air cleaner element. A fire or explosion
qt., 1.60 liter) could result.
With oil filter replacement: 2.0 US qt. (1.66 Imp qt.,
CAUTION
1.90 liter)
Never run the engine without the air cleaner. Rapid
Use 4-stroke motor oil that meets or exceeds the engine wear will result from contaminants, such as
requirements for API service classification SG or SH. dust and dirt being drawn into the engine.
Always check the API SERVICE label on the oil con-
tainer to be sure it includes the letters SG or SH. Kohler Engine
Air Pre-cleaner Service
Wash your hands with soap and water after handling
used oil. 1. Loosen the cover retaining knob and remove the
cover.
Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you 2. Remove the pre-cleaner from the paper element.
take it in a sealed container to your local service sta-
tion or recycling center for reclamation. Do not throw 3. Wash the pre-cleaner in warm water with detergent.
it in the trash, pour it on the ground or down a drain. Rinse the pre-cleaner thoroughly until all traces of
detergent are eliminated. Squeeze out excess
OIL FILTER water (do not wring). Allow the pre-cleaner to air
Change the oil, while the engine is still warm, as fol- dry.
lows:
1. Drain the engine oil. 4. Saturate the pre-cleaner with new engine oil.
Squeeze out all excess oil.
2. Remove the oil filter, and drain the oil into a suitable
container. Discard the used oil filter. 5. Reinstall the pre-cleaner over the paper element.
3. Clean the filter mounting base, and coat the gasket
of the new oil filter with clean engine oil. 6. Reinstall the air cleaner cover. Secure cover with
the cover retaining knob.
RANGER 200
D-3 D-3
MAINTENANCE
6. Check that the spark plug washer is in good condi-
AIR FILTER PAPER ELEMENT
tion and thread the spark plug in by hand to prevent
1. Loosen the cover retaining knob and remove the
cross-threading.
cover.
7. After the spark plug is seated, tighten with a spark
2. Remove the pre-cleaner from the paper element.
plug wrench to compress the washer.
•If installing a new spark plug, tighten 1/2 turn after
3. Remove the element cover nut, element cover, and
the spark plug seats to compress the washer.
paper element.
•If reinstalling a used spark plug, tighten 1/8 - 1/4 turn
after the spark plug seats to compress the washer.
4. Do not wash the paper element or use pressurized
•Spark Plug Torque: 20 ft. Lb. (27 N-m)
air, as this will damage the element. Replace a
dirty, bent, or damaged element with a new ele-
ment. Handle new elements carefully; do not use if
the sealing surfaces are bent or damaged.
CAUTION
5. When servicing the air cleaner, check the air clean-
The spark plug must be securely tightened. An
er base. Make sure it is secured and not bent or
improperly tightened spark plug can become very hot
damaged. Also check the element cover for dam-
and may cause engine damage.
aged or improper fit. Replace all damaged air
cleaner components.
Use only the recommended spark plug or equivalent.
A spark plug which has an improper heat range may
NOTE: Before air cleaner is reassembled make sure
cause engine damage.
rubber seal is in position around stud. Inspect, mak-
ing sure it is not damaged and seals with the element
cover. FUEL FILTER
6. Reinstall the paper element, pre-cleaner, element
1. Check the fuel filter for water accumulation or sedi-
cover, element cover nut, and air cleaner cover.
ment.
Secure cover with the cover retaining knob.
2. Replace the fuel filter if it is found with excessive
SPARK PLUG
water accumulation or sediment.
To ensure proper engine operation, the spark plug
must be properly gapped and free of deposits.
ENGINE ADJUSTMENT
WARNING
NOTE: Before removing spark plug, the muffler
WARNING
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.
OVERSPEED IS HAZARDOUS
The maximum allowable high idle speed for
1. Remove the spark plug cap.
this machine is 3750 RPM, no load. Do NOT
tamper with governor components or setting
2. Clean any dirt from around the spark plug base.
or make any other adjustments to increase
3. Use a plug wrench to remove the spark plug.
the maximum speed. Severe personal injury
and damage to the machine can result if
4. Visually inspect the spark plug. Discard them if the
operated at speeds above maximum.
insulator is cracked or chipped. Clean the spark
plug with a wire brush if it is to be reused.
Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
5. Measure the plug gap with a feeler gauge. Correct
Shop.
as necessary by bending the side electrode.
-Spark Plug Gap (.040 in.) (1.0 mm)
RANGER 200
D-4 D-4
MAINTENANCE
CHECKING THE ELECTROLYTE LEVEL
BATTERY MAINTENANCE
If battery cells are low, fill them to the neck of the filler
hole with distilled water and recharge. If one cell is
To access the battery, Remove the 3 screws from the
low, check for leaks.
rear battery tray using a screwdriver or a 3/8" socket.
Slide the battery tray out only far enough to access
CHARGING THE BATTERY
the battery terminals.
WARNING When you charge, jump, replace, or otherwise con-
nect battery cables to the battery, be sure the polarity
is correct. Improper polarity can damage the charging
GASES FROM BATTERY can explode. circuit. The RANGER 200 positive (+) battery terminal
q Keep sparks, flame and cigarettes has a red terminal cover.
away from battery.
If you need to charge the battery with an external
charger, disconnect the negative cable first, then the
To prevent EXPLOSION when:
positive cable before you attach the charger leads.
q INSTALLING A NEW BATTERY � disconnect After the battery is charged, reconnect the positive
negative cable from old battery first and connect to battery cable first and the negative cable last. Failure
new battery last. to do so can result in damage to the internal charger
q CONNECTING A BATTERY CHARGER � components.
remove battery from welder by disconnecting nega-
tive cable first, then positive cable and battery Follow the instructions of the battery charger manu-
clamp. When reinstalling, connect facturer for proper charger settings and charging time.
negative cable last. Keep well ventilated.
OPTION SPARK ARRESTER
USING A BOOSTER � connect positive lead to
q
battery first then connect negative lead to negative
battery lead at engine foot.
WARNING
BATTERY ACID can burn eyes and
skin.
MUFFLER MAY BE HOT
q Wear gloves and eye protection and
be careful when working near battery.
ALLOW ENGINE TO COOL BEFORE INSTALLING
q Follow instructions printed on battery.
THE SPARK ARRESTER!
CLEANING THE BATTERY DO NOT OPERATE ENGINE WHILE INSTALLING
THE SPARK ARRESTER!
Keep the battery clean by wiping it with a damp cloth
when dirty. If the terminals appear corroded, discon-
nect the battery cables and wash the terminals with an
ammonia solution or a solution of 1/4 pound (0.1113 Clean every 100 hours.
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 bat-
tery compartment, and surrounding areas with clear
water. Coat the battery terminals lightly with petrole-
um jelly or a non-conductive grease to retard corro-
sion.
Keep the battery clean and dry. Moisture accumula-
tion on the battery can lead to more rapid discharge
and early battery failure.
RANGER 200
D-5 D-5
MAINTENANCE
Welder/Generator Maintenance
STORAGE: Store the RANGER 200 in clean, dry pro-
tected areas.
CLEANING: Blow out the generator and controls peri-
odically with low pressure air. Do this at least once a
week in particularly dirty areas.
BRUSH REMOVAL AND REPLACEMENT: It’s nor-
mal for the brushes and slip rings to wear and darken
slightly. Inspect the brushes when a generator over-
haul is necessary.
Do not attempt to polish slip rings while the engine is
running.
WARNING
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.
RANGER 200
E-1 E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
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.
__________________________________________________________________________
Step 2. PERFORM EXTERNAL TESTS
This Troubleshooting Guide is provided to
The second column labeled "POSSIBLE
help you locate and repair possible machine
AREAS OF MISADJUSTMENT(S)" lists the
malfunctions. Simply follow the three-step
obvious external possibilities that may con-
procedure listed below.
tribute to the machine symptom. Perform
these tests/checks in the order listed. In
Step 1. LOCATE PROBLEM (SYMPTOM). general, these tests can be conducted with-
Look under the column labeled “PROB- out removing the case wrap-around cover.
LEMS (SYMPTOMS)�. This column
describes possible symptoms that the Step 3. RECOMMENDED COURSE OF
machine may exhibit. Find the listing that ACTION
best describes the symptom that the This column provides a course of action for
machine is exhibiting. the Possible Cause.If you do not under-
Symptoms are grouped into the following stand or are unable to perform the
categories: engine problems, function prob- Recommended Course of Action safely,
lems and output problems. contact you local Lincoln Authorized Field
Service Facility.
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.
CAUTION
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.
RANGER 200
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
Major Physical or Electrical Damage 1.If all recommended possible areas
is Evident. of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service
Facility.
Engine will not "crank". 1. Battery is low. 1.Charge Battery.
2. Loose battery cable connections. 2. Inspect, clean and tighten.
3. Faulty engine starter motor. 3. Contact authorized engine Service
Shop.
4. “Battery Circuit� circuit breaker is 4. Re-set. If it continues to trip, con
tripped. tact your local Lincoln AUTHO-
RIZED FIELD SERVICE FACILI-
TY.
Engine will "crank" but not start. 1. Out of fuel. 1. Fill tank and bleed fuel system. See
MAINTENANCE section
2. Faulty fuel solenoid or faulty PC 2. Contact your Local Lincoln Authorized
board or ignition system. Field Service Facility for technical
troubleshooting assistance.
Engine shuts down shortly after 1. Low oil level. 1. Change oil and oil filter and fill to prop-
starting. er level. Start engine and look for
leaks.
2. Faulty oil pressure switch or other 2. Contact your Local Lincoln Authorized
engine component. Field Service Facility or authorized
engine service shop.
3. Open rotor circuit. 3. Contact your Local Lincoln Authorized
Field Service Facility or authorized
engine service shop.
Battery does not stay charged. 1. Faulty battery. 1. Replace
2. Loose connections at battery or 2. Clean and tighten connections.
alternator.
3. Faulty engine alternator or charg- 3. Consult authorized Engine Service
er modual. Shop.
CAUTION
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.
RANGER 200
E-3 E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
Engine will not idle down to low 1. Idler switch in High idle position. 1. Set switch to Auto.
speed. 2. External load on welder or auxil- 2. Remove all external loads.
iary power.
3. Faulty PC board or idler solenoid. 3. Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
Engine will not go to high idle when 1. Poor work lead connection to 1. Make sure work clamp is tightly con-
attempting to weld. work. nected to clean base metal.
2. Faulty PC board. Low idle speed 2. Contact your Local Lincoln Authorized
set to low. Field Service Facility for technical
troubleshooting assistance.
Engine will not go to high idle when 1. Auxiliary power load is less than 1. Idler may not respond with less than a
using auxiliary power. 100 watts. 100 watt load. Set idler to "High".
2. Faulty PC board. 2. Contact your Local Lincoln Authorized
Field Service Facility for technical
troubleshooting assistance.
Engine does not develop full power. 1. Fuel filter clogged. 1. Replace.
2. Air filter clogged. 2. Clean or replace.
3. Fouled spark plugs. 3. Clean or replace.
4. Valves out of adjustment. 4. Contact authorized Engine Service
Shop.
CAUTION
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.
RANGER 200
E-4 E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
No welding power output. Thermal 1. Airflow is blocked or restricted. 1. Remove restriction and allow
shutdown light is on. machine to run until light goes off.
2. Welding current exceeding 2. Use smaller electrode size or
machine rating. slower wire feed speed. Allow
machine to run until light goes off.
No welding power output. Thermal 1. Remove restriction and allow 1. Make sure work clamp is tightly
shutdown light is NOT on. machine to run until light goes off. connected to clean base metal.
2. Use smaller electrode size or 2. Place switch in "Weld Terminals
slower wire feed speed. Allow On" position when welding without
machine to run until light goes off. control cable.
3. Faulty PC board or welder alter- 3. Contact your Local Lincoln
nator. AUTHORIZED FIELD SERVICE
FACILITY for technical trou-
bleshooting assistance.
Welder has output but no control. 1. Faulty control potentiometer or PC 1. Contact your Local Lincoln
board. AUTHORIZED FIELD SERVICE
FACILITY for technical trou-
bleshooting assistance.
No auxiliary power. 1. Open circuit breakers. 1. Reset breakers. If breakers keep
tripping, reduce power draw.
2. Faulty connections to auxiliary 2. Check connections.
receptacles.
3. GFCI tripped (if installed). 3. Clear any ground fault and reset
GFCI circuit by pressing "Reset"
button on the 120 V receptacle.
4. Faulty PC board or welder alterna- 4. Contact your Local Lincoln
tor. AUTHORIZED FIELD SERVICE
FACILITY for technical trou-
bleshooting assistance.
CAUTION
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.
RANGER 200
F-1
RANGER 200 - WIRING DIAGRAM
8
16
J1
Programing
R1 O U T P U T C O N T. P O T
W4 CC W
D1 - THREE PHASE BRIDGE RECTIFIER
9
1
10K
STATOR
W E LD
J50
D4 77 75
W IND IN G S 76
W3
B1
W8 3 2 1
4
8
B2
6 5 4
POS
W9 PCB 1 J2
B3
9 8 7 W1
B7
2 00 A MP Mode
MO DU L E
13
TWI STE D PAI R Selection
+
206S 204S C HO KE 23 3
1
5
6
+ W10 PC BOARD TO TS1
252
C1 HEAT SINK CONN.
R3
14
W R AP T W O T U R N S # 3 & # 6 23 2
6
3
250 OH MS
25 W ATT S
NEG
S HU N T 11
253 D2 DIODE
3 L E AD S I N D IR E C TI O N J3
50 M V =4 00 A M P S W6
MODULE
S H O W N T H R O U G H T O R O ID Machine
P50
1 2 3
12
20 6B 6 Selection
4 5 6
4
1
14
3 7 8 9
W2
H EA T S IN K W3
23
5
10
208B 25
26 1
T W IS T E D P A IR
260
J4
260A
261A
Meter
1
6
W7
20 8
5
10
4
2
FI E L D ID L ER C O N T R O L
S T A T O R A U X . W IND IN G 6
W I N D IN G 14 J5
3 P41-J41
13 25 1
S4
1
3
Meter
42 V A C 25 0
7 9
1
6
5 G ND -E
5
L2
S H O W N IN
10
118A
"A U T O PO S IT IO N " 206S
11 5A
11 6A P6-J6
204S
RF CHOKE
5L
1
2
Shunt
P42-J42
10 1A
4
2
10 5 A 76
12
11 P7-J7
1
6
77
1
3
Output
75
PCB2 ANALOG POWER PC BOARD
Control
6
2
4
3
J8
1
3
Hot Start
2
4
GND. SCREW ON B O T T O M G ND . S CR E W O N
CENTER BAFFLE
4 8 J9
IN S ID E O F C AS E F R O N T
208
1
3
GND-K Pinch/
206B 5L 20 0 B Arc Force
5H
GND-E
3
6
9
5G
5K
5
1 5 5F
20 9 J10
C E N T E R G ND . SCR E W O N
25A 14 Pin
7 D3
GND-M
IN S ID E O F C A S E F R O N T 3
1
4
C3
3 6 CB7 Ampenol
80 0u f
6
15 0 vdc
3
T O P G ND . SCR E W O N 21 2A
W H IT E 20 1 A
IN S ID E O F C A S E F R O N T 23 0
5C
23 2
1 4 5A
GND-L P11-J11
S1 S H O W N 21 2
20 0A 20 0
6
FRAM E G N D. 23 3
IDLE SOLENOID
IN "RU N " Thermal
23 1
6 12 5B PO SIT IO N
1
4
210C
210C
F RAM E G N D. 20 8B
8
G R E EN
S2
20 1
DIAGRAMS
S1
16
W H IT E 25 0
ST AR T
G ND -J 20 A 5H
LEAD COLOR CODE: 221
G ND -G BU T T O N 25 1
W H IT E
J102 B LA C K
G R E EN
21 5
215
P O S .B R U S H
B = BLACK OR GRAY 3D 3A 21 1 21 0D
N E G . B RU S H
CB1
R = RED OR PINK
P12-J12
21 1A
1 7 G ND -D S ILV E R
W = WHITE 5J
5A 20 A Sense/
G R EE N
3A
G = GREEN (W/YELLOW STRIPE) 26 0A
BL A C K
210A
B LA C K 21 0 B Idler/
T W IST ED P A IR 23
6E 6B
G N D -C 26 1A
CB2 RO TO R PWM
5C 25
J101
1
9
22 4B H O U R M E T E R
P O S IT IV E BRU S H C O NN EC T E D
3
8
4
+
W H IT E
11 6 A
T O S LIP R IN G N E A R E S T
SILV E R 5F
1 2 1 3 5B
1 4
1 1 5 105A
5J
T O T H E LA M IN A T IO N P13-J13
GREEN
35 A
10 1 A
3A
CB5 POWER
11 8 A
BL A C K 6B
3E 3 1 1 5A
2
1
3 4
5
4 6 20 9
5 8 6 10 J100 5G
35 A
3E 1 1 5/ 2 3 0 V
1 B LA C K
1
BLAC K
CB6
6 8 WHI T 6
6F PCB3 WELD CONTROL PC BOARD
229
6B
4
E
21 0
22 4
2
212A 225 12 V O LT
W H IT E
TE RM. 5C
12 + BA T T E R Y
16
7 9
1
3
221
228
P34-J34
E L E C T RI CA L SYMB O L S P E R E 1 5 3 7
PCB7 BATTERY DISPLAY
1 2 34
C O N N E C T O R S V I E W E D F R OM I N S E R TIO N E N D
22 4
A LL C A S E F R O N T C O M P O N E N T S S H O W N V IEW ED F R O M R E A R .
FRAME
8
16
GROUND
21 0 22 4B
GND P
P AN EL R EC EPT AC LE C AV ITY N U M BERI N G SEQ U ENC E 22 8
207 GND H ENGINE
AC 21 0 B
FUEL
AC B 231
(V IEWE D F R OM LEA D S IDE O F R EC EPT AC LE) B-
4
+ SHUTOFF
2
21 0D 22 9
GROUND
P43-J43
SOLENOID 20 0
321
1
123 21 1
KOHLER ENGINE COMPONENTS
3
654 5K
456 230
987 225
GND J
1
9
789 P33-J33
PCB6 THERMAL DISPLAY
9 PIN 9 PIN PCB4 BATTERY PC BOARD
J50 P50
E-RW
G3653
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..
F-1
F-2
DIMENSION PRINT RANGER 200
10.28 10.78
24.86
2.6
7.22
"A"
20.80
36.24
33.62
CENTER OF GRAVITY WITH OIL IN
ENGINE AND EMPTY FUEL TANK 29.88
"B"
42.10
17.50 19.50
41.20
M19410
TRUCK/UNDERCARRIAGE MOUNTING HOLES
F-2
F-3 F-3
NOTES
F-4 F-4
NOTES
RANGER 200
Now Available...12th Edition New Lessons in Arc Welding
The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques;
With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects,
since 1933, the Procedure Handbook is considered by many to such as distortion; and supplemental information on arc
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187 pages with more than 100 illustrations. Size 8-1/2� x 11� Lincoln Welding School
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Check or Money Order Enclosed, U.S. Funds only
Credit Card - Telephone: _______________________________________________
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Signature as it appears on Charge Card:
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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
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
BOOKS OR FREE INFORMATIVE CATALOGS
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
q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION q Aislese del trabajo y de la tierra.
French q Ne laissez ni la peau ni des vête- q Gardez à l’écart de tout matériel q Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
q Isolez-vous du travail et de la terre.
German q Berühren Sie keine stromführenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamáveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
q Isole-se da peça e terra.
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 HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
q Keep your head out of fumes. q Turn power off before servicing. q Do not operate with panel open or
WARNING
q Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
Spanish
q Los humos fuera de la zona de res- q Desconectar el cable de ali- q No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
q Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
q Débranchez le courant avant l’entre- q N’opérez pas avec les panneaux
q Gardez la tête à l’écart des fumées.
tien. ouverts ou avec les dispositifs de
q Utilisez un ventilateur ou un aspira-
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
ED
German
q Strom vor Wartungsarbeiten q Anlage nie ohne Schutzgehäuse
q Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
1 SED
WARNUNG
nen; Maschine anhalten!) Betrieb setzen!
q Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
W ER
Portuguese
q Não opere com as tampas removidas. q Mantenha-se afastado das partes
q Mantenha seu rosto da fumaça.
q Desligue a corrente antes de fazer moventes.
q Use ventilação e exhaustão para
ATENÇÃO
serviço. q Não opere com os paineis abertos
remover fumo da zona respiratória.
IM P
q Não toque as partes elétricas nuas. ou guardas removidas.
E SU
S Japanese
SE Y
NT
Chinese
RA
AR
Korean
W
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� World's Leader in Welding and Cutting Products �
� 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
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