RETURN TO MAIN MENU RANGER 3 PHASE ™ IM929 January, 2007 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 thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ........................................................................................................A-2 Machine Grounding ...................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - RANGER 3 PHASE (K2337-2) INPUT - GASOLINE ENGINE Make/Model Description Kohler CH23S 2 cylinder 4 Cycle Air-Cooled Gasoline Engine. Aluminum Alloy with Cast Iron Liners, Electronic Ignition Horsepower Operating Displacement Speed (RPM) cu. in. (cu.cm.
A-2 A-2 INSTALLATION SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. -----------------------------------------------------------------------ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing.
INSTALLATION A-3 VEHICLE MOUNTING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components 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 stable under conditions of use. • Do not exceed maximum rated loads for components such as suspension, axles and tires. • Mount equipment base to metal bed or frame of vehicle.
A-4 ANGLE OF OPERATION Internal combustion engines are designed to run in a level condition which is where the optimum performance 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 maintaining the oil at the normal (FULL) oil capacity in the crankcase in a level condition.
A-5 A-5 INSTALLATION CONNECTION OF THE LN-25 TO THE RANGER 3 PHASE • • Shut the welder off. Connect the electrode cable from the LN-25 to the“ELECTRODE” terminal of the welder. Connect the work cable to the “TO WORK” terminal of the welder. • Position the welder “Polarity” switch to the desired polarity, either DC (-) or DC (+). • Position the “RANGE” switch to the “WIRE FEED” position.
A-6 A-6 INSTALLATION GND Y 480 V Z X 120 V 240 V 120 V* GND (FOR ALL SINGLE AND THREE PHASE LOADS) *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.
A-7 A-7 INSTALLATION TABLE lll ELECTRICAL DEVICE USE WITH THE RANGER 3 PHASE. Type Common Electrical Devices 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 capacitative elements to fail.
A-8 INSTALLATION AUXILIARY POWER WHILE WELDING Simultaneous welding and power loads are permitted by following Table I. The permissible currents shown assume that current is being drawn from either the 120V or 240V supply (not both at the same time). Also, the “Output Control” is set at “10” for maximum auxiliary power. TABLE I SIMULTANEOUS WELDING AND POWER*** Output Selector Setting * Permissible Power Watts (Unity Power Permissible Auxiliary Current in Amperes Factor) @ 120V *-or- @ 240V Max.
A-9 A-9 INSTALLATION Figure 1 CONNECTION OF RANGER 3 PHASE TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 60 Hz. 3-Wire Service 120 VOLT COMPANY 120 VOLT METER NEUTRAL BUS N LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.
B-1 OPERATION 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 electrically live parts or electrode with skin or wet clothing.
B-2 B-2 OPERATION “ 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 STICK/TIG (constant current) (3 range settings) WIRE FEED (constant voltage) (one range setting) Range Setting Current Range 90 Max. 50 to 90 Amps 145 Max. 70 to 145 Amps 210DC/225AC Max. 120 to 210 (DC) 225(AC) 15 to 25V Up to 200 Amps CAUTION Never change the “RANGE” Switch setting while welding.
B-3 B-3 OPERATION WELDING PROCESS SETTINGS FOR 1% THORIATED TUNGSTEN For any electrodes the procedures should be kept within the rating of the machine. For electrode information see the appropriate Lincoln publication. TUNGSTEN DIAMETER (in.) 1/8 3/32 1/16 RANGE SWITCH SETTINGS APPROXIMATE CURRENT RANGE 90, 145, or 210 90 or 145 90 or 145 80 - 225 Amps 50 - 180 Amps 45 - 120 Amps STICK (CONSTANT CURRENT) WELDING Connect welding cables to the "TO WORK” and "ELECTRODE” studs. Start the engine.
B-4 B-4 OPERATION SUMMARY OF WELDING PROCESSES CONTROL CABLE USED IDLE MODE ELECTRODE WHEN NOT WELDING STICK No AUTO Hot Touch electrode to work. Welding starts immediately and engine goes to high idle. WIRE FEED, LN-25 WITH INTERNAL CONTACTOR No AUTO Cold Press gun trigger, LN-25 contactor closes. Welding starts immediately and engine goes to high idle.
B-5 B-5 OPERATION STARTING/SHUTDOWN INSTRUCTIONS STARTING THE ENGINE 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. WARNING • Do not touch electrically live parts of electrode with skin or wet clothing. • Keep flammable material away. Stop the engine by placing the Engine switch in the “OFF” position.
C-1 OPTIONAL EQUIPMENT ACCESSORIES (Field Installed) 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 & Light Kit K965-1 Cable Storage Rack K889-2 & -3 TWO-WHEEL UNDERCARRIAGE - For moving by hand. Overall Width 29 in (.
C-2 ACCESSORIES C-2 RECOMMENDED EQUIPMENT STICK TIG K704 Accessory Kit which includes: PRO TORCH® TIG Torch K1783-9 PTA 26V TIG Torch • Electrode Holder & Cable • Work Clamp & Cable • Headshield Magnum Parts Kit and Argon Gas •KP509 Parts Kit 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.
D-1 D-1 MAINTENANCE 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 maintenance 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.
D-2 MAINTENANCE 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 container to be sure it includes the letters SG or SH. • Refer to the maintenance section of the Engine Owner’s Manual for the maintenance schedule, spark plug servicing, cooling system servicing, and fuel filter replacement. SAE 10W-30 is recommended for general, all-temperature use, -5 F to 104 F (-20 C to 40 C).
D-3 D-3 MAINTENANCE ENGINE ADJUSTMENTS WARNING GASES FROM BATTERY can explode. • Keep sparks, flame and cigarettes away from battery. OVERSPEED IS HAZARDOUS To prevent EXPLOSION when: • INSTALLING A NEW BATTERY - disconnect negative cable from old battery first and connect to new battery last. 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.
E-1 TROUBLESHOOTING E-1 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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE No auxiliary power from the GFCI receptacle. 1. GFCI Receptacle may have tripped. Follow “GFCI Receptacle Testing and Resetting Procedure” in the MAINTENANCE section of this manual. Engine will not go to high idle when using auxiliary power. 1. 2. GFCI may be tripped-see above No voltage signal from the current sensor. Auxiliary power load less than 100 to 150 watts. Faulty P.C.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine will not crank or is hard to crank. Engine shuts down. POSSIBLE CAUSE 1. Battery will not hold a charge. Faulty Battery. 2. No or insufficient charging current. 3. Loose battery cable connection(s). 1. Out of fuel. 2. Low oil level. Engine does not develop full power. 1. Engine is hard to start.
RANGER 3 PHASE 224 AC B+ V 5E U 3 4 STARTER SOLENOID 1 2 211 IDLER SOLENOID 209A CR1 P5 J5 209A 5D U = BLUE V = VIOLET SILVER COLORED 3A TERMINALS (WHITE WIRES) ENGINE CROSS SUPPORT ENGINE FOOT CB3 20A 11 1 3 6 12 W1 J1 3 2 1 S2 E 254 8 10 5L 120V GFCI 5 NEUT 5K 6B 3A 3B 120V GFCI J2 5L HOT NEUT HOT X CB4 20A LEAD X FROM STATOR TO PASS THROUGH TOROID ONCE (NOT SHOWN) IN SAME DIRECTION AS LEAD 6.
TO WORK RANGER 3 PHASE USE PO POLARITY SWITCH CH TO T SET FOR F DESI SIRE RED D ELEC ELECTRODE ODE P POLARIT RITY.. PO POSI SITION ON THE E OUTPUT OU SELECT S CTOR RE FEED (CV) PO POSITION. T E WIRE SWITCH TTO THE N.B. N. ELECT ECTRODE ODE CABL CABLE WELDING WE CABLE E MUST BE B SIZED SIZ D FOR F R CURRENT CU DUTY D CYCLE C OF O APPLICA ICATION. TO WORK W TO WORK W A.02 DIAGRAMS M20266 WORK CLIP LEAD N.A. ELECTRODE ELE CTRODE LN-15 OR LN-25 RE FFEEDER EDER WIRE Keep guards in place. place.
RANGER 3 PHASE 9.09 17.00 9.31 9.09 10.19 9.59 26.59 OIL FILTER REMOVAL CENTERLINE OF SHAFT 30.27 10.33 8.80 21.22 22.15 RANGER 3 PHASE (KOHLER) 42.25 42.00 30.00 M20397 B.
NOTES RANGER 3 PHASE
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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