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IM10030
®
November, 2010
RANGER 3 PHASE
For Machines with Code Number 11619
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 I NSTALL,
OPERATE OR REPAI R THI S
EQUI PMENT W I THOUT READ-
I NG THI S M ANUAL AND THE
SAFETY PRECAUTI ONS CON-
TAI NED THROUGHOUT. And,
most importantly, think before you
act and be careful.
OPE
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS 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 POSSIbLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• 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 Linco
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vi vi TAbLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions ........................................................................................................A-2 Machine Grounding.....................................................
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A-1 A-1 INSTALLATION TEChNICAL SPECIFICATIONS - RANGER® 3 PhASE ( K2337-3) INPUT - GASOLINE ENGINE Make/Model Description Operating Displacement Capacities horsepower Starting Speed (RPM) cu. in. System (cu.cm.) 2 cylinder High Idle 3700 12VDC 4 Cycle Battery Air-Cooled Electric Start Fuel: Gasoline Kohler 41.1(674) Full Load 3500 Group 58 12 Gal (45.4 L) 23 HP @ Engine. CH23S Battery Lubricating Oil: 3600 RPM Aluminum Alloy (435 cold 2.0 Qts. (1.9 L) with Cast Iron Low Idle 2200 Cranking Li
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A-2 A-2 INSTALLATION When this welder is mounted on a truck or trailer, it’s SAFETY PRECAUTIONS frame must be electrically bonded to the metal frame of the vehicle. Use a #8 or larger copper wire connect- WARNING ed between the machine grounding stud and the Do not attempt to use this equipment until you frame of the vehicle. have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes Where this engine driven welder is connected to important safety precautions
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A-3 A-3 INSTALLATION 3. Proper placement of the equipment on the trailer to FUEL insure stability side to side and front to back when being moved and when standing by itself while Fill the fuel tank with clean, fresh, lead-free gasoline. being operated or serviced. Observe fuel sight gauge in the base of the machine while filling to prevent overfilling. 4. Typical conditions of use, i.e., travel speed; rough- ness of surface on which the trailer will be operated; environmental conditions. WA
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A-4 A-4 INSTALLATION WELDING OUTPUT CAbLES ADDITIONAL SAFETY PRECAUTION With the engine off, connect the electrode and work cables to the studs provided. These connections WARNING should be checked periodically and tightened if neces- • Lift only with equipment of sary. Loose connections will result in overheating of adequate lifting capacity. the output studs. • be sure machine is stable when lifting. When welding at a considerable distance from the welder, be sure you use ample size welding
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A-5 A-5 INSTALLATION • Position the “RANGE” switch to the “WIRE FEED LOCATION / VENTILATION CV” position. The welder should be located to provide an unrestrict- • Attach the single lead from the LN-25 control box ed flow of clean, cool air to the cooling air inlets and to to the work using the spring clip on the end of the avoid heated air coming out of the welder recirculating lead - it carries no welding current. back to the cooling air inlet. Also, locate the welder so • Place the engine
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A-6 A-6 INSTALLATION 120/240 VOLT DUAL VOLTAGE RECEPTACLE WELDER OPERATION WELDER OUTPUT The 120/240 volt receptacle can supply up to 40 • Maximum Open Circuit Voltage at 3700 RPM is 80 amps of 240 volt power to a two wire circuit, up to 40 Volts RMS. amps of 120 volts power from each side of a three • Duty Cycle is the percentage of time the load is wire circuit (up to 80 amps total). Do not connect the being applied in a 10 minute period. For example, a 120 volt circuits in parallel. Cur
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A-7 A-7 INSTALLATION MOTOR STARTING 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 Most 1.5 hp AC single phase motors can be started if there is function. Using a NEMA plug L16-20P, connect either X and Y no load on the motor or other load connected to the machine, or X and Z to the receptacle, as well as the machine ground. X (T FH G OR R NE D A E L L P H SA IN S 4 G E 8L 0 L E Y V O Z A AN DD S ) since the f
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A-8 A-8 INSTALLATION 1. Install a double pole, double throw switch between AUXILIARY POWER WhILE WELDING the power company meter and the premises dis- connect. Simultaneous welding and power loads are permitted by following Table I. The permissible currents shown Switch rating must be the same or greater than the assume that current is being drawn from either the customer’s premises disconnect and service over- 120V or 240V supply (not both at the same time). current protection. Also, the “Ou
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A-9 A-9 INSTALLATION Figure A.1 CONNECTION OF RANGER® 3 PhASE TO PREMISES WIRING WARNING Connection of RANGER® 3 PhASE to premises wiring must be done by a licensed electrician and must comply with the National Electrical Code and all other applicable electrical codes. See the INSTALLATION section for important information about not using 480V 3 Phase receptacle for con- nection to single Phase Premisis Wiring. RANGER® 3 PhASE
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b-1 b-1 OPERATION SAFETY PRECAUTIONS WELDER CONTROLS - FUNCTION AND Do not attempt to use this equipment until you OPERATION have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes ENGINE SWITCh important safety precautions, detailed engine The engine switch is used to Start the Engine, Select starting, operating and maintenance instructions, High Idle or Auto Idle while the engine is running, and and parts lists. stop the Engine. ---------------------------
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b-2 b-2 OPERATION “ RANGE” SWITCh The “Range” switch is used to select one of four amperage ranges with generous overlap for Stick/TIG welding, or one Wire Feed welding range. Process Range Setting Current Range STICK/TIG 90 Max. 40 to 90 Amps (constant current) 145 Max. 70 to 145 Amps (3 range settings) 225 MAX 120 to 225 Amps WIRE FEED (constant voltage) 15 to 25V Up to 200 Amps (1 range setting) CAUTION Never change the “RANGE” Switch setting while welding. This will dam
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b-3 b-3 OPERATION STARTING/ShUTDOWN INSTRUCTIONS STOPPING ThE ENGINE STARTING ThE ENGINE Remove all welding and auxiliary power loads and allow engine to run at low idle speed for a few minutes WARNING to cool the engine. • Do not touch electrically live parts Stop the engine by placing the Engine switch in the of electrode with skin or wet “OFF” position. clothing. A fuel shut off valve is not required on the RANGER® 3 PHASE because the fuel tank is mounted below the engine. • Keep flammable ma
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b-4 b-4 OPERATION WELDING PROCESS The RANGER® 3 PHASE can be used with a broad For any electrodes the procedures should be kept range of DC stick electrodes. See “Welding Tips 1” within the rating of the machine. For electrode infor- included with the RANGER® 3 PHASE for electrodes within the rating of this unit and recommended weld- mation see the appropriate Lincoln publication. ing currents of each. STICK (CONSTANT CURRENT) WELDING SCRATCh START TIG (CONSTANT CURRENT) WELDING Connect welding
