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Lincoln Electric RANGER IM929 User's Manual

1. Xe uc a Sal HIE Weal AMI W ous il el all Quali Y O aual ai 293931 gl o as slt All usa JS dan ule Y Jio wae Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos OA VE U DOMTORRIER THEW 9 z Vi S BET freA eis Jo al gh Ad AIX ole Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo A HAUSHERMRELTTF EU OMAR RSR ez 119 59 HEHA die ule Lilly gupay alg Daun 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 BEFOL
2. 1 is Lincoln s K957 1 If the user adapts a non Lincoln trailer 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 equipment 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 4 Typical conditions of use i e travel speed rough ness of surface on which the trailer will be operat ed environmental conditions 5 Conformance with federal state and local laws 1 1 Consult applicable federal state and local laws regarding specif ic requirements for use on public highways RANGER 3 PHASE LINCOLN 5 A 3 VEHICLE MOUNTING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other compo nents to fail Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is sta ble under conditions of use Do not exceed maximum rated loads for components such as suspension axles and tires Mount equipment b
3. F 3 8 H 496 A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS RANGER 3 PHASE K2337 2 INPUT GASOLINE ENGINE Make Model Description Horsepower Operating Displacement Starting Capacities Speed RPM cu in System cu cm 5 High Idle 3700 Wou Air Cooled Battery Gasoline 23 HP Electric Start Fuel Engine 3600 RPM Full Load 3500 41 674 Group 58 9 Gal 34 L Aluminum Alloy Kohler Kohler Battery Lubricating Oil with Cast Iron 435 cold 2 0 Qts 1 91 Liners Low Idle 2200 Cranking Electronic Amps Ignition RATED OUTPUT SR BEEN WELDER eee Constant Current 225A 25V 100 DC Constant Current 210A 25V 10096 DC Constant Voltage 200A 20V 10096 RATED OUTPUT 104 F 40 C GENERATOR Auxiliary Power 11 500 Watts Peak 10 500 Watts Continuous 3 Phase 60 Hz AC 480V 10 500 Watts Peak 9500 Watts Continuous Single Phase 60 Hz AC 120V 240V PHYSICAL DIMENSIONS WEIGHT 538 lbs 244kg 1074 mm 1 Output rating in watts is equivalent to volt amperes at unity factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced RANGER 3 PHASE LINCOLN 5 2 INSTALLATION 2 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engi
4. JHL SSOMNDV SZ N1 ANY 61 1 3SVHd AIONVA RANGER 3 PHASE LINCOLN F 3 16 0CN TWAOWSY 431111 TIO Si mero 606 DIAGRAMS NYL 1305 1105 ANY NON N lO ALIAVYS 40 83 LN39 F 3 LAVHS 40 SANTYSLNA9 PA M31HOM 3SVHd HIONVA RANGER 3 PHASE LINCOLN E NOTES RANGER 3 PHASE LINCOLN 5 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes 0 los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra o REPOR ELE het EE LATE OMLMPT APSSAPREBS NTUSHILT FSU e E GUB MIU AER GH Oa CRM ER
5. 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 3 PHASE LINCOLN 5 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION No auxiliary power from the GFCI receptacle Engine will not go to high idle when using auxiliary power No welder output power Engine will not idle down to low speed Engine will not go to high idle when attempting to weld GFCI Receptacle may have tripped Follow GFCI Receptacle Testing and Resetting Procedure in the MAINTENANCE section of this manual GFCI be tripped see above No voltage signal from the current sensor Auxiliary power load less than 100 to 150 watts Faulty P C Board Open in miscellaneous leads Open lead in flashing or field If all recommended possible areas of misadjustment have been checked and the problem persists Contact circuit your local Lincoln Authorized Faulty rotor Faulty Potentiometer R1 Faulty stator Field winding Faulty Field rectifier D2 Faulty P C Board Idler switch on High Idle Insufficient voltage present between terminals 213 and 5E Voltage should be 12V DC External load on welder or auxiliary power Faulty
6. 480 Volt 3 Phase Receptacle with Ground The 480 volt receptacle can supply 12 6 amps of 3 phase power or up to 15 amps of single phase power A NEMA plug L16 20P is required to use this receptacle The ground GND connection is connect ed to the machine frame it is NOT the neutral of the three phase connection and should under no circum stances be connected to the neutral of any 3 phase load Do not connect 480V 3 phase to single phase premises wiring If 480 volt single phase load is to be run the X lead must be one of the leads in the circuit in order for the automatic idle to function Using a NEMA plug L16 20P connect either X and Y or X and Z to the recep tacle as well as the machine ground All auxiliary power is protected by circuit breakers with the following values Y A 480 V nz e 2 ND FOR ALL SINGLE AND THREE PHASE LOADS The 120V has 20 amp circuit breakers for each duplex receptacle The 240V has 50 amp circuit breakers for each hot lead going the 240V receptacle The 480V 3 phase circuit breakers switch has a 3 phase 15 amp circuit breaker Ground Wire Periodically check the ground wire at plugs power cords and auxiliary loads to ensure that the grounding circuit is intact and connected MOTOR STARTING Most 1 5 hp AC single phase motors can be started if there is no load on the motor or other load connected to the machine since the full load current rating of
7. LINCOLN 5 Mar 93 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s
8. Where this engine driven welder is connected to premises wiring such as that in your home or shop it s frame must be connected to the system earth ground See further connec tion instructions in the section entitled Standby Power Connections as well as the article on grounding in the lat est National Electrical Code and the local code In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints or to the metal framework of a building which has been effectively grounded The National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol is pro vided on the front of the welder SPARK ARRESTER Some federal state or local laws may require that gasoline engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations the K894 1 spark arrester must be installed and properly maintained CAUTION incorrect arrester may lead to damage to the engine or adversely affect performance TOWING The recommended trailer for use with this equipment for road in plant and yard towing by a
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10. 030 GAP Oil capacity increases from 2 0 Qts to 2 1 Qts when using this filter RANGER 3 PHASE LINCOLN 5 1 TROUBLESHOOTING 1 HOW 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility
11. Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 5 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before
12. hands with soap and water after handling used oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station or recycling center for reclamation Do not throw it in the trash pour it on the ground or down a drain OIL FILTER CHANGE Drain the engine 2 Remove the oil filter and drain the oil into a suitable container Discard the used oil filter 8 Clean the filter mounting base and coat the gasket of the new oil filter with clean engine oil 4 Screw on the new oil filter by hand until the gasket contacts the filter mounting base then use an oil fil ter socket tool to tighten the filter an additional 1 2 to 7 8 turn 5 Refill the crankcase with the specified amount of the recommended oil Reinstall the oil filler cap 6 Start the engine and check for oil filter leaks 7 Stop the engine and check the oil level If neces sary add oil to the upper limit mark on the dipstick AIR CLEANER AND OTHER MAINTENANCE e Air Cleaner With normal operating conditions the maintenance schedule for cleaning and re oiling the foam pre filter is every 25 hours and replacement of the air cleaner filter every 100 hours More frequent servicing is required with dusty operating condi tions Refer to the maintenance section of the Engine Owner s Manual for more information MAINTENANCE D 2 Refer to the ma
13. steps to assure load is limited to the capacity of the RANGER 3 PHASE by installing a 40 amp 240V double pole circuit breaker Maximum rated load for the 240V auxiliary is 40 amperes Loading above 40 amperes will reduce output voltage below the allowable 10 of rated voltage which may damage appliances or other motor driven equipment Install a 50 amp 120 240V plug NEMA type 14 50 to the Double Pole Circuit Breaker using No 8 4 conductor cable of the desired length The 50 amp 120 240V plug is available in the optional plug kit Plug this cable into the 50 amp 120 240V recepta cle on the RANGER 3 PHASE case front RANGER 3 PHASE LINCOLN 5 9 INSTALLATION 9 Figure 1 CONNECTION RANGER 3 PHASE PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR GC Ge VER P di 60 Hz 3 Wire COMPANY E Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES E DISCONNECT AND SERVICE GROUND OVERCURRENT 240 VOLT PROTECTION DOUBLE POLE CIRCUIT 240 VOLT BREAKER 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 1 50 AMP 120 240 VOLT Eu ee NOTE No 6 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS A WARNING Connection of RANGER 3 PHASE to premises wiring must be done by a licensed electrician and must comply with the Nationa
14. 120V or 240V supply not both at the same time Also the Output Control is set at 10 for maximum auxiliary power TABLE SIMULTANEOUS WELDING AND POWER Permissible Power Watts Unity Power Factor Output Selector Setting Permissible Auxiliary Current in Amperes 120V or 240V ESS Feed Setting None Each duplex receptacle is limited to 20 amps Not to exceed 40A per 120VAC branch circuit when splitting the 240 VAC output Use of 3 Phase AC poower is not recommended while welding STANDBY POWER CONNECTIONS The RANGER 3 PHASE is suitable for temporary standby or emergency power using the engine manu facturer s recommended maintenance schedule The RANGER 3 PHASE can be permanently installed as a standby power unit for 240V 3 wire single phase 40 ampere service A WARNING Connections must be made by a licensed electri cian who can determine how the 120 240V power can be adapted to the particular installation and comply with all applicable electrical codes The following information can be used as a guide by the electrician for most applications refer also to the connection diagram shown in Figure 1 INSTALLATION 1 A 8 Install a double pole double throw switch between the power company meter and the premises dis connect Switch rating must be the same or greater than the customer s premises disconnect and service over current protection Take necessary
15. ETTINGS APPROXIMATE CURRENT RANGE 1 8 90 145 or 210 80 3 32 90 or 145 1 16 90 or 145 225 Amps 50 180 Amps 45 120 Amps The K930 TIG Module should be used with the RANGER 3 PHASE on high idle to maintain satisfac tory operation It can be used in the AUTO position but the delay going to flow idle after welding is ceased will be increased if the AFTER FLOW CONTROL is set above 10 seconds WIRE FEED WELDING PROCESSES CONSTANT VOLTAGE The Innershield electrode recommended for use with the RANGER 3 PHASE is NR 212 MP The elec trode sizes and welding ranges that can be used with the RANGER 3 PHASE are shown in the following table Diameter Wire Speed in Range In Min Approximate Current Range 75A to 120A 120A to 170A 125A to 210A 80 110 70 130 The RANGER 3 PHASE is recommended for limited welding GMAW gas metal arc welding The recommended electrodes are 030 and 035 L 50 and L 56 They must be used with a blended shielding gas such as C25 75 Argon 25 CO The welding ranges that can be used with the RANGER 3 PHASE are shown in the following table Diameter Wire Speed Approximate in Range In Min Current Range 80 110 75A to 120A 70 130 120A to 170A ARC GOUGING The RANGER 3 PHASE can be used for limited arc gouging Set the Range switch to adjust output current to the desired level for the gouging electrode being used acco
16. GEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n 0 aspiraci n para gases Gardez la t te a l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRcocuc 9 fsUPBHEILTASESUCFEU EUR Ea fE e za SH7IAE else e SUAS MAS sis PARAH 587E Assis Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico e N o toque as partes el tricas nuas e X7TTLA UAVCRUD PSB gt e SAUTER Do not operate with p
17. Gas Cylinder for use on K1770 1 Undercarriage One or two may be installed on an undercarriage K1788 1 ROLL CAGE Gives added damage protection Attaches to K1737 1 K1770 1 and K957 1 K886 1 CANVAS COVER To protect the RANGER 3 PHASE when not in use Made from attractive red canvas material which is flame retardant mildew resistant and water repellent K802R POWER PLUG KIT provides four 120V plugs rated at 15 amps each and one dual voltage Full KVA plug rated at 120 240V 50 amps K802N POWER PLUG KIT Provides four 120V plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240V 50 amps K704 ACCESSORY KIT Includes 35 ft 10 7m 2 0 AWG electrode cable 30 ft 9 1m 2 0 AWG work cable head shield Filterplate work clamp and electrode holder 400 Amp Capacity C 1 K875 ACCESSORY KIT Includes 20 ft 6 1m 26 elec trode cable headshield filter plate work clamp electrode holder and sample pack of mild steel electrodes 150 Amp Capacity lug 15ft 4 6 46 work cable K894 1 SPARK ARRESTER KIT Includes a heavy gauge Steel approved spark arrester and clamp for easy mounting to muffler exhaust pipe K1816 1 FULL KVA ADAPTER KIT Plugs into the 120 240V NEMA 14 50R receptacle on the case front which accepts 4 prong plugs and converts it to a NEMA 6 50R receptacle which accepts 3 prong plugs T12153 9 FULL KVA POWER PLUG One dual voltage plug rated at 120 240V 50 amps
18. K930 2 TIG MODULE Provides high frequency and shield ing gas control for AC and DC GTAW TIG welding applica tions lts compact case is designed foe easy carrying com plete with a handle High frequency bypass is built in Requires K938 1 Contactor Kit K936 4 Control Cable and K814 Arc Start Switch K938 1 CONTACTOR KIT For use with TIG Module Provides a cold electrode until the triggering device Arc Start Switch is pressed K936 4 CONTROL CABLE Connects TIG Module to RANGER 3 PHASE 9 Pin to 115V Plug K814 ARC START SWITCH Attaches to the TIG torch for convenient finger control K937 45 CONTROL CABLE EXTENSION Allows TIG Module to be operated at distances up to 200ft from the power source Available in 45ft 13 7m Sections K939 1 DOCKING KIT For Mounting the K930 2 TIG Module on top of the RANGER 3 PHASE RANGER 3 PHASE LINCOLN 5 C 2 RECOMMENDED EQUIPMENT STICK K704 Accessory Kit which includes Electrode Holder amp Cable Work Clamp amp Cable Headshield WIRE FEED LN 25 K449 LN 25 Includes internal contactor for across the arc operation no control cable Provides cold electrode until gun trigger is pressed Includes gas solenoid Requires Drive Roll Kit and Weld Power Cable Magnum Gun and Magnum Gun Connector Kit are required for gas shielded welding Innershield Gun is required for gasless welding LN 15 K449 LN 15 Includes internal contactor for acr
19. LOADS WITHIN THE RATING OF THE MACHINE AVOID LONG IDLE RUNNING PERIODS REMOVE LOADS AND ALLOW ENGINE TO COOL BEFORE SHUTDOWN The engine manufacturer s recommendation for the running time until the first oil change is as follows KOHLER CH23S 5 HRS The oil filter is to be changed at the second oil change Refer to the Engine Owner s Manual for more information RANGER 3 PHASE LINCOLN 5 C1 ACCESSORIES OPTIONAL EQUIPMENT K957 1 HEAVY DUTY TWO WHEEL TRAILER FOR SMALL WELDERS For road off road and in plant and yard towing For highway use consult applicable federal state and local laws regarding requirements for brakes lights fenders etc Order K957 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 2 Fender amp Light Kit K965 1 Cable Storage Rack Field Installed K889 2 amp 3 TWO WHEEL UNDERCARRIAGE For moving by hand Overall Width 29 in 74m Both have pneumatic tires Puncture proof tires included with K889 3 K1737 1 FOUR WHEEL ALL TERRAIN UNDER CARRIAGE For moving by hand at construction sites Heavy duty puncture resistant pneumatic tires K1770 1 UNDERCARRIAGE FACTORY For mov ing by hand on a smooth surface One or two gas cylinders can be mounted on the rear of the undercar riage with the installation of K1745 1 Cylinder Holder s Heavy duty puncture resistant pneumatic tires and front caster K1745 1 WELDING GAS CYLINDER LPG TANK HOLDER Holds Welding
20. Possible Concerns Resistive Heaters toasters incandescent light bulbs electric range hot pan skillet coffee maker NONE Capacitive TV sets radios microwaves appliances with electrical control Voltage spikes or high voltage regulation can cause the capac itative elements to fail Surge protection transient protection and additional loading is recom mended for 100 fail safe operation DO NOT RUN THESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS Inductive Single phase induction motors drills well pumps grinders small refrigerators weed and hedge trimmers These devices require large current inrush for starting Some synchronous motors may be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures Capacitive Inductive Computers high resolution TV sets complicated electrical equipment An inductive type line condition er along with transient and surge protection is required and liabilities still exist DO NOT USE THESE DEVICES WITH A RANGER 3 PHASE The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect ed to the RANGER 3 PHASE RANGER 3 PHASE LINCOLN 5 A 8 AUXILIARY POWER WHILE WELDING Simultaneous welding and power loads are permitted by following Table The permissible currents shown assume that current is being drawn from either the
21. R The LN 15 has an internal contactor and the electrode is not energized until the gun trigger is closed When the gun trigger is closed the wire will begin to feed and the welding process is started a Shut the welder off b Set the Polarity switch to the desired polarity either DC or DC c Attach the single lead from the front of the LN 15 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current Set the RANGE switch to the WIRE FEED CV position e Place the Engine switch in the Auto Idle position f Adjust the wire feed speed at the LN 15 and adjust the welding voltage with the output CONTROL at the welder Output CONTROL must be set above 3 Note LN 15 Control Cable model will not work with the RANGER 3 PHASE RANGER 3 PHASE LINCOLN 5 5 INSTALLATION 5 CONNECTION OF THE LN 25 THE RANGER 3 PHASE e Shut the welder off e Connect the electrode cable from the LN 25 to the ELECTRODE terminal of the welder Connect the work cable to the TO WORK termi nal of the welder e Position the welder Polarity switch to the desired polarity either DC or DC e Position the RANGE switch to the WIRE FEED position e Attach the single lead from the LN 25 control box to the work using the spring clip on the end of the lead it carries no wel
22. RANGER PHASE For Machines with Code Number 11419 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 OPERATOR S MANUAL ISO 9001 ANSI RAB Fa Se EN 7 CAS Designed and Manufactured Under a Quality Program Certified by LI NCOLN e Copyright 2007 Lincoln Global Inc World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com l WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM PO
23. SSIBLE 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 amp 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 ca 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 9 ELECTRIC AND RS MAGNETIC FIELDS 88 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 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 bef
24. Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use suitable clothing made from durable flame resistant 5f AUG 06 LINCOLN 5 material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable no
25. a 1 5 hp motor is approximately 20 amperes 10 amperes for 240 volt motors The motor may be run at full load when plugged into only one side of the duplex receptacle Larger motors through 2 hp can be run provided the receptacle rating as previously stated is not exceeded This may necessitate 240V operation only The 480 volt 3 phase output of the RANGER 3 PHASE is capable of running most 480VAC 3 phase motors up to 10HP 10HP motor must be started with no load on the motor and no other load connect ed to the machine since the full load current of a 10HP 480VAC 3 phase motor is approximately 12 5 amps Refer to the reconnect phase output to any load the ground at the 3 phase receptacle is NOT the neutral of 3 phase connection and should under no circumstance be connected to the neutral of any 3 phase load RANGER 3 PHASE Extension Cord Length Recommendations Use the shortest length extension cord possible sized per the following table Gurrent Vatage Load Amps Volts Watts 130 9 50 15 88 27 138 42 225 69 pem 15 240 3600 60 18 69 350 107 600 183 20 20 4800 60 18 30 53 275 _ 84 450 137 40 240 9500 50 15 90 27 150 _ 46 225 69 Conductor size is based on maximum 2 0 voltage drop RANGER 3 PHASE LINCOLN 5 INSTALLATION TABLE Ill ELECTRICAL DEVICE USE WITH THE RANGER 3 PHASE Type Common Electrical Devices
26. anel open or guards off No operar con panel abierto 0 guardas quitadas e N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas THE L EUITTF 585 9 SER HGTBI BUSUR RE SERB x e wel Me z WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG it ie BIR Chinese aadi oe lue chal TAU Gall bacs ga d arin Mall oe us Aie by pha NM uu 0 Jl ale AREY cuts UI ai tha Jada e Aale Cut Al dl LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR HRA CL TRHOKRERE HAM SUCR t D RES AMEN o SALAD HAY zeit AS PSP HHCH alal dl illai al Gail guet Ca L LINCOLN World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www
27. ange set the OUTPUT Control at 10 For minimum output within a selected range set the OUTPUT Control at 5 Control settings below 5 may reduce arc stabili ty For best overall welding performance set the RANGE Switch to the lowest setting and the OUT PUT Control near the maximum to achieve the desired welding current RANGE SETTING TYPICAL CURRENT RANGE ELECTRODE SIZE 90 MAX 3 32 50 TO 90 AMPS 125 MAX 70 TO 145 AMPS 120 TO 210 DC 225 AC AMPS 210 DC 225 AC 5 32 MAX The RANGER 3 PHASE can be used with a broad range of AC and DC stick electrodes See Welding Tips 1 included with the RANGER 3 PHASE for elec trodes within the rating of this unit and recommended welding currents of each TIG CONSTANT CURRENT WELDING The K930 TIG Module installed on a RANGER 3 PHASE provides high frequency and shielding gas control for AC and DC GTAW TIG welding process es The TIG Module allows full range output control After flow time is adjustable from 0 to 55 seconds When using the RANGER 3 PHASE for AC TIG weld ing of aluminum the following settings and electrodes are recommended SETTINGS FOR PURE TUNGSTEN TUNGSTEN DIAMETER in RANGE SWITCH SETTINGS APPROXIMATE CURRENT RANGE 1 8 90 or 145 80 3 32 90 or 145 150 Amps 45 130 Amps 1 16 90 40 80 Amps OPERATION SETTINGS FOR 1 THORIATED TUNGSTEN TUNGSTEN DIAMETER in RANGE SWITCH S
28. anual before starting for the first time Remove all loads connected to the AC power recepta cles Use the choke control as follows KOHLER ENGINE Always pull the choke control out when starting the engine cold warm or hot Turn the engine switch to the start 6 position and crank the engine until it starts Release the switch as soon as the engine starts slowly return the choke control to the full in position choke open and turn the switch to the Auto de 62 lt gt position Do not turn the switch to the start position while the engine is running because this will cause damage to the ring gear and or starter motor After running at high engine speed for 10 14 seconds the engine will go to low idle Allow the engine to warm up by letting it run at low idle for a few minutes STOPPING THE ENGINE Remove all welding and auxiliary power loads and allow engine to run at low idle speed for a few minutes to cool the engine Stop the engine by placing the Engine switch in the OFF position A fuel shut off valve is not required on the RANGER 3 PHASE because the fuel tank is mounted below the engine BREAK IN PERIOD It is normal for any engine to use a greater amount of oil until the break in is accomplished Check the oil level twice day during the break in period mately 50 running hours IMPORTANT ORDER TO ACCOMPLISH THIS BREAK IN THE UNIT SHOULD BE SUBJECTED TO MODERATE
29. arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 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 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 Also see item 1 b 6 SAFETY gt WELDING and CUTTING gt SPARKS 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 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 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 Do no
30. ase to metal bed or frame of vehi cle Follow vehicle manufacturer s instructions PRE OPERATION SERVICE CAUTION READ the engine operating and maintenance instruc tions supplied with this machine A WARNING Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling GASOLINE Wipe up spilled fuel and allow can cause fire fumes to clear before starting explosion engine Do not overfill tank fuel expansion may cause overflow GASOLINE FUEL ONLY gi Fill the fuel tank with clean fresh lead free gasoline Observe fuel gauge while filling to prevent overfilling WARNING Damage to the fuel tank may cause fire or explosion Do not drill holes in the RANGER 3 PHASE base or weld to the RANGER 3 PHASE base LUBRICATION SYSTEM CAPACITY INCLUDING FILTER Kohler 235 2 0 Quarts 1 9 Liters The RANGER 3 PHASE is shipped with the engine crankcase filled with SAE 10W 30 oil Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required FUEL OIL INSTALLATION A 3 Make certain that the oil filler cap is tightened securely Refer to the engine Owners Manual for specific oil recom mendations BATTERY CONNECTIONS CAUTION Use caution as the electrolyte is a strong acid that can burn skin and damage eyes This welder is s
31. d ground Always wear dry insulating gloves e ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 3 SX 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 throughout this operator s manual and the Engine manual as well Read the Safety Precautions in the front of this manual and the engine instruction manual before working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair cloth ing and tools away from gears fans and all other moving parts when starting operating or repairing the equipment ROUTINE MAINTENANCE e Atthe end of each day s use refill the fuel tank to minimize moisture condensation in the tank Running out of fuel tends to draw dirt into the fuel system Also check the crankcase oil level and add oil if indicated CAUTION Make certain that the oil filler cap is securely tight ened after checking or adding oil If the cap is not tight oil consumption can increase significantly which may be evidenced by white smoke coming from the exhaust OIL Maintenance schedule for changing the oil and oil filter after break in Kohler CH23S Oil Filter 200 Hrs The above schedule is for normal operating condi tions More frequent oil changes a
32. ding current e Place the engine switch in the AUTO position e Adjust wire feed speed at the LN 25 and adjust the welding voltage with the output CONTROL at the welder NOTE The welding electrode is energized at all times unless an LN 25 with built in contactor is used If the output CONTROL is set below 3 the LN 25 contactor may not pull in CONNECTION OF K930 2 TIG MODULE TO THE RANGER 3 PHASE The TIG Module is an accessory that provides high frequency and shielding gas control for AC and DC GTAW TIG welding See IM528 supplied with the TIG Module for installation instructions Note The TIG Module does not require the use of a high frequency bypass capacitor However if the RANGER 3 PHASE is used with any other high fre quency equipment the bypass capacitor must be installed order kit T12246 INSTRUCTIONS ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the roof and case sides in place as this provides maximum protection from moving parts and assures proper cooling air flow 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 WELDER OPERATION WELDER OUTPUT Maximum Open Circuit Voltage at 3700 RPM is 80 Volts RMS Duty Cycle is the percentage of time the load is being applied in a 10 minute period For example a 60 duty cycle represents 6 mi
33. e GFCI recepta cle The night light or other product should go OFF Push the Reset button again The light or other product should go ON again If the light or other product remains ON when the Test button is pushed the GFCI is not working prop erly or has been incorrectly installed miswired If your GFCI is not working properly contact a qualified certified electrician who can assess the situation rewire the GFCI if necessary or replace the device RANGER 3 PHASE LINCOLN 5 D 3 ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS A WARNING The maximum allowable high idle speed for this machine is 3750 RPM no load Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at speeds above maximum Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop SLIP RINGS A slight amount of darkening and wear of the slip rings and brushes is normal Brushes should be inspected when a general overhaul is necessary If brushes are to be replaced clean slip rings with a fine emery paper CAUTION Do not attempt to polish slip rings while engine is running MAINTENANCE A WARNING GASES FROM BATTERY can explode A Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconn
34. e casi annees B 3 Staning the EN B 3 sis puces sosta B 3 EE B 3 Break In IP Qn EE B 3 Welding reet B 4 Stick Constant Current Welding ss B 4 TIG Constant Current Welding senem B 4 Wire Feed Welding Processes Constant B 4 GOUGNO B 4 Summary of Welding Processes B 5 ees stead Section Optional C 1 Recommended Equipment issusnesseenenmeminstee nuneenenneines C 2 meets Section D Safety D 1 Routine Engine Oil Oil Filter and Air Cleaner Maintenance D 1 D2 Engine Adjustments tenue eau Drs a ERR pua D 3 SIP EE D 3 Battery Maintenance Engine Maintenance D 3 Troubleshooting WE Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guilde ecce ndr n dert nh an E 2 E 3 Wiring Diagrams amp Dimension Print sens Section F Wiring and Connection Diagrams sisi F 1 F 2 DIMENSION dde
35. e e WE A 2 Spark Arrester sisi A 2 Towing Vehicle Mounting 21er tein E 2 VeNicle og me A 3 Pre Operation Engine 4 42 in A 3 USN A 3 A 3 Battery ENER A 3 Welding Cable Connections A 3 Angle of Operation nenne A 4 PE 4 High Altitude Operaliori 4 LOCATON ANG Kn E e EE 4 irte inre RE A 4 Connection of Wire Feeders ser 4 Connection of Tig Module sic 5 Additional Safety Precautions Welding Operation Output A 5 Auxiliary Power and Receptacles A 5 A 6 Motor Starting and Extension Cord Length Table A 6 Electrical Device Used with the Ranger 10 000 A 7 Auxiliary Power While Welding Standby Power Connections A 8 Premises TE A 9 le Section B Safety B 1 General Description sise B 1 Welder Controls Function and Operation B 1 Range and Control Dial Polarity sn B 2 Startin Shutdown InstructiOrls irse ace cede ca
36. ect negative cable from old battery first and connect to new battery last CONNECTING A BATTERY CHARGER Remove bat tery from welder by disconnecting negative cable first then positive cable and battery clamp When rein stalling connect negative cable last Keep well venti lated USING A BOOSTER connect positive lead to battery first then connect negative lead to 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 1 When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed Failure to observe the proper polarity could result in damage to the charging circuit The positive battery cable has a red terminal cover If the battery requires charging from an external charger disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads Failure to do so can result in damage to the internal charger components When reconnecting the cables connect the positive cable first and the negative cable last HARDWARE Both English and Metric fasteners are used in this welder m ENGINE MAINTENANCE PARTS KOHLER C23S KOHLER 12 050 01 FRAM 8172 FRAM CA79 KOHLER 24 083 02 Air Filter KOHLER 47 083 03 Element Air Filter Pre Cleaner KOHLER 24 050 10 CHAMPION RC12YC
37. h setting while welding This will damage the switch e CONTROL DIAL Provides a fine welding current adjustment within the Range Switch settings in the STICK mode and weld ing voltage control with the Range switch set in the wire feed mode POLARITY SWITCH Provides three selectable welding polarities AC DC amp DC CAUTION Never change the Polarity switch setting while welding This will damage the switch RANGER 3 PHASE APPROXIMATE FUEL CONSUMPTION KOHLER 23 COMMAND 2200 RPM i 3700 RPM 2 86 Liters Hour AC CC Weld Output 1 23 Gallons Hour 225 Amps 25 Volts 4 64 Liters Hour DC CC Weld Output 1 38 Gallons Hour 210 Amps 25 Volts 5 21 Liters Hour 200 Amps 20 Volts 4 60 Liters Hour 9 500 Watts 5 77 Liters Hour Auxiliary Power 3 Phase 1 64Gallons Hour RANGER 3 PHASE LINCOLN B 3 WELDING PROCESS For any electrodes the procedures should be kept Within the rating of the machine For electrode infor mation see the appropriate Lincoln publication STICK CONSTANT CURRENT WELDING Connect welding cables to the TO WORK and ELECTRODE studs Start the engine Set the Polarity switch to the desired polarity The RANGE switch markings indicate the maximum current for that range as well as the typical electrode size for that range The OUTPUT Control provides fine adjust ment of the welding current within the select range For maximum output within a selected r
38. hipped with the negative battery cable dis connected Make sure that the Engine Switch is in the STOP position and attach the disconnected cable securely to the negative battery terminal before attempting to operate the machine If the battery is discharged and does not have enough power to start the engine see the battery charging instructions in the Battery section NOTE This machine is furnished with a wet charged bat tery if unused for several months the battery may require a booster charge Be careful to charge the battery with the correct polarity WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the studs provided These connections should be checked periodically and tightened if necessary Loose con nections will result in overheating of the output studs When welding at a considerable distance from the welder be sure you use ample size welding cables Listed below are copper cable sizes recommended for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES 225 Amps 100 Duty Cycle 0 100 Ft 0 31m 100 200 Ft 31 61m 200 250 Ft 61 72 m 1 0 AWG RANGER 3 PHASE LINCOLN 5 4 INSTALLATION 4 ANGLE OPERATION Internal combusti
39. intenance section of the Engine Owner s Manual for the maintenance schedule spark plug servicing cooling system servicing and fuel filter replacement Blow out the machine with low pressure air period ically In particularly dirty locations this may be required once a week Output Ranger Selector and Polarity Switches Switch contacts should not be greased To keep contacts clean rotate the switch through its entire range frequently Good practice is to turn the han dle from maximum to minimum setting twice each morning before starting to weld GFCI RECEPTACLE TESTING AND RESET TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped To properly test and reset the GFCI receptacle If the receptacle has tripped first carefully remove any load and check it for damage If the equipment has been shut down it must be restarted The equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equipment is providing at least 80 volts to the receptacle input terminals The circuit breaker for this receptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI recep tacle This will assure normal GFCI operation Plug a night light with an ON OFF switch or other product such as a lamp into the GFCI receptacle and turn the product ON Push the Test button located on th
40. is de energized to shut down the engine When held in the START position the engine starter motor is energized When in HIGH IDLE position the engine will run continuously at high idle When in AUTO IDLE lt position the engine will run continuously and the idler operates as follows e Welding When the electrode touches the work the welding arc is initiated and the engine accelerates to full speed After welding ceases and no auxiliary power is being drawn the engine will return to low idle after approximately 10 to 14 seconds e Auxiliary Power With the engine running at low idle and auxiliary power for lights or tools is drawn approximately 100 150 watts or greater from the receptacles the engine will accelerate to high speed If no power is being drawn from the receptacles and not welding for 10 14 seconds the idler reduces the engine speed to low idle RANGER 3 PHASE LINCOLN 5 OPERATION B 2 RANGE SWITCH The Range switch is used to select one of three amperage ranges with generous overlap for Stick TIG welding or one Wire Feed welding range Process Range Setting Current Range STICK TIG 90 Max 50 to 90 Amps constant current 145 Max 70 to 145 Amps 3 range settings 210DC 225AC Max 120 to 210 DC 225 AC WIRE FEED constant voltage 15 to 25V Up to 200 Amps one range setting CAUTION Never change the RANGE Switc
41. l Electrical Code and all other applicable electrical codes See the Installation Section for important information about not using the 480V 3 Phase Receptacle for connection to Single Phase Premises Wiring RANGER 3 PHASE LINCOLN 5 B 1 OPERATION B 1 SAFETY PRECAUTIONS 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 elecirically live parts or electrode with skin or wet clothing eInsulate yourself from work and ground Always wear dry insulating gloves Always operate the welder with the hinged door closed and the side panels in place Read carefully the Safety Precautions page before operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Instruction Manual GENERAL DESCRIPTION The RANGER 3 PHASE is a twin cylinder gasoline driven multiprocess arc welder and AC power gener ator It is built in a heavy gauge steel case for durabili ty on the job site WELDER CONTROLS FUNCTION AND OPERATION ENGINE SWITCH The engine switch is used to Start the Engine Select High Idle or Auto Idle while the engine is running and stop the Engine When placed in the OFF position the ignition circuit
42. lincolnelectric com
43. n flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the
44. ne manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e 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 3 MOVING PARTS can injure 2 Do not operate with doors open or guards off e Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual MACHINE GROUNDING Because this portable engine driven welder or generator creates it s own power it is not necessary to connect it s frame to an earth ground unless the machine is connected to premises wiring your home shop etc A WARNING To prevent dangerous electric shock other equipment to which this engine driven welder supplies power must be grounded to the frame of the welder using a grounded type plug or be double insulated Do not ground the machine to a pipe that carries explosive or combustible material When this welder is mounted on a truck or trailer it s frame must be electrically bonded to the metal frame of the vehi cle Use a 8 or larger copper wire connected between the machine grounding stud and the frame of the vehicle
45. nutes of load and 4 minutes of no load in a 10 minute period Duty Cycle for the RANGER 3 PHASE is 100 RANGER 3 PHASE Constant Current 225 Amps AC Q 25 Volts 210 Amps DC Q 25 Volts Constant Voltage 200 Amps DC Q 20 Volts AUXILIARY POWER CAUTION Do not connect any plugs that connect to the power receptacles in parallel Start the engine and set the IDLER control switch to the High Idle mode Set the CONTROL to 10 Voltage is now correct at the receptacles for auxiliary power This must be done before a tripped receptacle can be reset properly See the MAINTE NANCE section for more detailed information on test ing and resetting the GFCI receptacle The RANGER 3 PHASE can provide both three phase and single phase power up to 11 500 watts of 480 volts AC three phase 60Hz power for peak use and up to 10 500 watts of 480 volts AC three phase 60Hz power for continuous use up to 10 500 watts of 120 240 volts AC single phase 60Hz power for peak use and up to 9 500 watts of 120 240 volt AC single phase 60Hz power for continuous use The front of the machine includes four receptacles for connecting the AC power plugs one 20 amp 480 volt 3 phase NEMA receptacle one 50 amp 120 240 volt NEMA 14 50R receptacle and two 20 amp 120 volt NEMA 5 20R receptacles Output voltage is within 10 at all loads up to rated capacity Do not use 3 phase power and single phase power simultaneously All au
46. on engines are designed to run in a level condition which is where the optimum perfor mance is achieved The maximum angle of operation for the engine is 15 degrees from horizontal in any direction If the engine is to be operated at an angle provisions must be made for checking and maintain ing the oil at the normal FULL oil capacity in the crankcase in a level condition When operating at an angle the effective fuel capaci ty will be slightly less than the specified 9 gallons 34 Liters LIFTING The RANGER 3 PHASE weighs approximately 575 lbs 261kg with full tank of gasoline A lift bail is mounted to the machine and should always be used when lifting the machine A WARNING Lift only with equipment of ade quate lifting capacity Be sure machine is stable when lift ing Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder FALLING EQUIPMENT can cause injury Do not lift machine if lift bail is damaged Do not operate machine while suspended from lift bail HIGH ALTITUDE OPERATION At higher altitudes Welder output de rating may be neces sary For maximum rating de rate the welder output 3 5 for every 1000ft 305m above 3000ft 914m If operation will consistently be at altitudes above 5 000 ft 1525m a carburetor jet designed for high altitudes should be installed This will result in better fuel economy cleaner exha
47. ore refueling to prevent spilled fuel from vaporiz ing 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to In some cases it may be necessary to remove safety nes alle minimize exposure to EMF fields from the welding circuit 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 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 1 f Do not put your hands near the engine fan Do not attempt to override the idler by pushing on the throttle control rods while the engine is running 2 d 3 Do n
48. oss the arc operation no control cable Provides cold electrode until gun trigger is pressed Includes gas solenoid Requires Drive Roll Kit and Weld Power Cable Magnum Gun and Magnum Gun Connector Kit are required for gas shielded welding Magnum Innershield Gun and wire bushing is required for gas less welding ACCESSORIES TIG PRO TORCH TIG Torch K1783 9 PTA 26V TIG Torch Magnum Parts Kit and Argon Gas 509 Parts Kit K930 2 TIG Module Requires Requires K938 1 Contactor Kit K936 4 Control Cable and K814 Arc Start Switch Optional TIG Module Accessory K939 1 Docking Kit e K937 45 Control Cable Extensions 45ft RANGER 3 PHASE LINCOLN 5 D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING Have qualified personnel do the maintenance work Turn the engine off before working inside the machine 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 mainte nance requiring their removal is complete Always use the greatest care when working near moving parts Do not put your hands near the engine cooling blower fan If a problem cannot be corrected by following the instructions take the machine to the nearest Lincoln Field Service Shop ELECTRIC SHOCK can kill not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work an
49. ot place your body between the electrode work cables If the electrode cable is on your right side the work cable should also be on your right side D K Connect the work cable to the workpiece as close as possible to the area being welded 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 Do not work next to welding power source Mar 95 LINCOLN 5 SAFETY ELECTRIC SHOCK can kill The electrode and work or ground circuits 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
50. particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information 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 Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you
51. rding to the ratings in the following table CARBON DIAMETER in CURRENT RANGE DC electrode positive 1 8 30 60 Amps 5 32 90 150 Amps 3 16 200 250 Amps RANGER 3 PHASE LINCOLN 5 p OPERATION SUMMARY OF WELDING PROCESSES ELECTRODE WHEN NOT PROCESS WELDING WIRE FEED LN 25 WITH INTERNAL CONTACTOR TIG TIG MODULE WITH WITH CONTACTOR KIT CONTROL CABLE amp ARC START SWITCH WIRE FEED LN 15 ACROSS the ARC has internal contactor RANGER 3 PHASE LINCOLN TO START WELDING Touch electrode to work Welding starts immediately and engine goes to high idle Press gun trigger LN 25 contactor closes Welding starts immediately and engine goes to high idle NOTE Output Control must be set above 3 Press Arc Start Switch contactor closes welding starts immediately Press gun trigger LN 15 contactor closes Welding starts immediately Note Output Control must be set above 3 B 5 OPERATION B 5 STARTING SHUTDOWN INSTRUCTIONS STARTING THE ENGINE WARNING e Do not touch electrically live parts of electrode with skin or wet clothing Keep flammable material away Insulate yourself from work and ground Wear eye ear and body protection Keep your head out of the fumes Use ventilation or exhaust to remove fumes from breathing zone 2e id Be sure all Pre Operation Maintenance has been per formed Also read the Engine Owner s M
52. re required with dusty high temperature and other severe operating conditions Refer to the maintenance section of the Engine Owner s Manual for more information NOTE Engine life will be reduced if the oil and oil filter are not changed according to the manufacturer s recommendation ENGINE OIL CHANGE CA Drain the oil while the engine is warm to assure rapid and complete draining e Remove the oil filler cap and dipstick Remove the yellow cap from the oil drain valve and attach the flexible drain tube supplied with the machine Push in and twist the drain valve counterclockwise Pull the valve out and drain the oil into a suitable contain er e Close the drain valve by pushing in and twisting clockwise Replace the yellow cap e Refill to the upper limit mark on the dipstick with the recommended oil Tighten the oil filler cap securely ENGINE OIL REFILL CAPACITIES Without oil filter replacement e 1 7qt 1 6 liter Kohler With oil filter replacement e 2 0qt 1 9 liter Kohler RANGER 3 PHASE LINCOLN 5 D 2 Use 4 stroke motor oil that meets or exceeds the requirements for API service classification SG or SH Always check the API SERVICE label on the oil con tainer to be sure it includes the letters SG or SH SAE 10W 30 is recommended for general all tempera ture use 5 F to 104 F 20 C to 40 C See Engine Owner s Manual for more specific informa tion on oil viscosity recommendations Wash your
53. request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page 5 Section TECHNICAL Specifications Em A 1 Safety Precautions nicieni 2 Machine ele o
54. rte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc pe
55. s Jo ov eet LHOdANS 85080 aw HOI Weg NOLLINOI ANIONS hionastos HOLIMS 53 HALUVLS WN ao 1003 N 277 9 NNOD 339 I7 018 8 a Ovec Vico ws 92 VAL IOHLNO9 Andino MODO IWYS NI 3ONO GIOHOL S3SSVd X AYTI SNOLLIMIQ 3LISOddO NI GIOHOL NAHL 2 9 ONY SAYT 40801 S3SSVd 75250 31 0 MAYS as HAMOTNO YILIN HNOH M349S GNNOYD 4 1724 GION31OS SR aai 39 YSZ velz 180 LLZ ANOJ3SVO NO V60Z 3SVHd H39NVH RANGER 3 PHASE LINCOLN E DIAGRAMS F 2 F 2 99c0cIN NOLLISOd AO SHIM OL HOLIMS M019373S LNdLNO IHL NOLLISOd ALMY10d 1 0818 G3MIS3G LIS OL HOLIMS ALINY TOd ISN NOLLVOrTddv 30 71949 ALNG LNSYYND O43 03215 LSNW 318 2 ON OM 38V9 30041938 ON OL lt OL 5 4751 di 430333 JHM GC N1 siu eojues 10 spred Ajeoun eje yono jou oq e H eJojeq 7 pee iepeg JALLVO3N 320000080 e uedo sjeued uy ejeJedo jou og e MU ULO SLYVd IID YOOHS 01410313 ONINHVM NOLLO3NNOO
56. t 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and folllow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101
57. ust and longer spark plug life It will not give increased power Contact your local authorized engine service shop for high altitude jet kits that are available from the engine manufacturer CAUTION Do not operate with a high altitude jet installed at alti tudes below 5000 ft This will result in the engine run ning too lean and result in higher engine operating temperatures which can shorten engine life Muffler Relocation WARNING Shut off welder and allow muffler to cool before touching muffler The RANGER 3 PHASE is shipped with the exhaust coming out on the left side The exhaust can be changed to the opposite side by removing the two screws that hold the exhaust port cover in place and installing the cover on the opposite side Operating the RANGER 3 PHASE without the cover in place will result in a higher noise level and no increase in machine output LOCATION VENTILATION The welder should be located to provide an unrestrict ed flow of clean cool air to the cooling air inlets and to avoid heated air coming out of the welder recirculating back to the cooling air inlet Also locate the welder so that engine exhaust fumes are properly vented to an outside area STACKING RANGER 3 PHASE machines cannot be stacked CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off welder before making any electrical connections WIRE FEED CONSTANT VOLTAGE CONNECTION OF LN 15 ACROSS THE ARC WIRE FEEDE
58. uvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER HR TRANSFORMATEUR ET Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier
59. wiring in solenoid circuit Faulty idler solenoid Faulty P C Board Poor work lead connection to work No voltage signal from the current sensor No open circuit voltage on output studs Faulty P C Board Field Service Facility 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 3 PHASE LINCOLN 5 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual Engine will not crank or is hard to Battery will not hold a charge crank Faulty Battery No or insufficient charging current Loose battery cable connection s If all recommended possible areas of Engine shuts down Out of fuel misadjustment have been checked and the problem persists Contact Low oil level your local Lincoln Authorized Field Service Facility Engine does not develop full power 1 Fuel filter clogged Air filter clogged Engine is hard to start Spark plugs do not have specified gap Spark plugs are fouled 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 3 PHASE LINCOLN 5 YT
60. working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations PR CAUTIONS DE SURETE Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes 6 S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des po
61. xiliary power is protected by cuircuit breakers 120 240 VOLT DUAL VOLTAGE RECEPTACLE The 120 240 volt receptacle can supply up to 40 amps of 240 volt power to a two wire circuit up to 40 amps of 120 volts power from each side of a three wire cir cuit up to 80 amps total Do not connect the 120 volt circuits in parallel Current sensing for the automatic idle feature is only in one leg of the three wire circuit as shown in the following column RANGER 3 PHASE LINCOLN 5 6 INSTALLATION 6 GND TN 120 V t 240V H ry 120 Y Current Sensing for Automatic Idle Receptacle viewed from front of Machine 120 V GFCI DUPLEX RECEPTACLES A GFCI Ground Fault Circuit Interrupter electrical receptacle is a device to protect against electric shock should a piece of defective equipment connected to it develop a ground fault If this situation should occur the GFCI will trip removing voltage from the output of the receptacle If a GFCI receptacle is tripped see the MAINTENANCE section for detailed information on testing and resetting it A GFCI receptacle should be properly tested at least once every month The 120V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current load through the associated receptacle

Lincoln Electric RANGER IM929 User's Manual

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