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R RANGER 8+ DIESEL
IM612
™ April, 1998
RANGER 8 + DIESEL
For use with machines having Code Numbers: 10533
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 ac
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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 ELECTRIC SHOCK can ARC RAYS can burn. 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 SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provoquer un échau
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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! 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
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vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Installation Instructions.........................................................................................................A-2 Location and Ventilation............................................
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vii TABLE OF CONTENTS Page Maintenance ....................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance.............................................................................................D-1 Engine Adjustments...............................................................................................D-2
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - RANGER 8+ DIESEL (K1632-1) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System Ruggerini 2 cylinder High Idle 3700 51.9 cu. in 12VDC battery Fuel: 9.0 gal. RD 201 4 Cycle Low Idle 2200 (851 cc) 34.0 L Diesel Engine Air Cooled Diesel Full Load 3500 w/Direct Injection Horsepower Oil: 3.2 Qts. Diecast Aluminum 3.0 L Crankcase 18.4 HP @ 3600 RPM RATED OUTPUT - WELDER Welding Output Volts at Rated Amps D
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A-2 A-2 INSTALLATION Always operate the RANGER 8+ DIESEL with the INSTALLATION INSTRUCTIONS case roof on and all machine components completely assembled. This will protect you from the dangers of SAFETY PRECAUTIONS moving parts, hot metal surfaces, and live electrical devices. WARNING STORING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes 1. Store the machine in a cool, dry place when it is not impo
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A-3 A-3 INSTALLATION 4. Typical conditions of use, i.e., travel speed; rough- ness of surface on which the undercarriage will be operated; environmental conditions; likely mainte- nance. (1) 5. Conformance with federal, state and local laws. (1) Consult applicable federal, state and local laws regarding specific requirements for use on public highways. LIFTING The RANGER 8+ DIESEL weighs approximately PRE-OPERATION ENGINE SERVICE 695 lbs/315 kg. A lift bail is mounted to the machine frame an
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A-4 A-4 INSTALLATION FUEL IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN: Fill the fuel tank with clean No. 2, diesel fuel only. Do a) Installing new batteries. not fill to the top of the filler neck to allow room for b) Using a booster. expansion. Use correct polarity — Negative Ground. The RANGER 8+ DIESEL has a 9 gallon (34 liter) fuel The RANGER 8+ DIESEL is shipped with the negative tank with a top fill and fuel gauge mounted on the fuel battery cable disconnected. Before you operate
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A-5 A-5 INSTALLATION ELECTRICAL CONNECTIONS TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES See Figure B.1 in the OPERATION section of this 250 Amps 250 Amps manual for the location of the 115 and 230 volt recep- 40% Duty Cycle 100% Duty Cycle tacles, weld output terminals, circuit breakers and ground stud. 3 AWG 1 AWG 0-50 Ft. MACHINE GROUNDING 3 AWG 1 AWG 50-100 Ft. Because the RANGER 8+ DIESEL creates its own 2 AWG 1 AWG 100-150 Ft. power from its diesel-engine driven generator, a
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A-6 A-6 INSTALLATION AUXILIARY POWER RECEPTACLES, PREMISES WIRING PLUGS, AND HAND-HELD EQUIPMENT The RANGER 8+ DIESEL is suitable for temporary, standby, or emergency power using the engine manu- The control panel of the RANGER 8+ DIESEL fea- facturer’s recommended maintenance schedule. With tures three auxiliary power receptacles: See Figure its three-wire grounded neutral generator, it can be B.1. permanently installed as a standby power unit for 230 volt, three wire, single phase 40 amper
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A-7 A-7 INSTALLATION Figure A.1 CONNECTION OF RANGER 8+ DIESEL TO PREMISES WIRING 230 VOLT GROUNDED CONDUCTOR POWER 230 Volt 115 VOLT 60 Hz. COMPANY 3-Wire 115 VOLT Service METER NEUTRAL BUS N LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. PREMISES DISCONNECT AND SERVICE GROUND OVERCURRENT 40AMP PROTECTION 230 VOLT DOUBLE POLE 50 AMP, 115/230 CIRCUIT VOLT PLUG 230 VOLT BREAKER NEMA TYPE 14-50 GND N 50 AMP, 115/230 VOLT NO
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B-1 B-1 OPERATION AC/DC TIG WELDING (Constant Current) GENERAL DESCRIPTION � AC & DC TIG Welding Can be Done at All Constant The RANGER 8+ DIESEL is a diesel-engine driven, Current Output Range Settings. multi-process AC and DC arc welder and AC power generator for commercial and residential applications. As a generator it can supply up to 9,000 continuous watts of 115/230 volt, 60 Hz, single-phase AC power AUXILIARY POWER at unity power factor to operate AC power tools, bat- tery chargers, and
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B-2 B-2 OPERATION DIESEL ENGINE LIMITATIONS � The RANGER 8+ DIESEL is not recommended for Ruggerini - RD 201 features: any processes besides those that are normally per- formed using stick welding (SMAW), TIG welding � Air cooled, twin cylinder. (GTAW), MIG (GMAW) welding and Innershield® (FCAW) welding. � Direct injection. � The RANGER 8+ DIESEL is not recommended for pipe thawing. � Crankcase in diecast aluminium. � During welding, generator power is limited and out- � Forced lubrication with
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B-3 B-3 OPERATION ting of the OUTPUT RANGE SELECTOR. Never CONTROLS AND SETTINGS change the polarity switch setting while welding since this could damage the switch. All generator/welder controls are located on the Output Control Panel of the machine case front. 4. ENGINE STOP PULL CABLE: Allows the operator Diesel engine idler control, and start/stop controls are to STOP the diesel engine by pulling out this con- also on the case front. See Figure B.1 and the expla- trol cable until the engi
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B-4 B-4 OPERATION 10. WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER) WITH FLANGE NUT: Provides the con- nection point for the electrode holder cable. 11. WELD OUTPUT TERMINAL (TO WORK) WITH FLANGE NUT: Provides the connection point for the work cable. 12. GROUND STUD: Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. 13. 50 AMP, 115/230 VOLT RECEPTACLE: Connection point for supplying 230 volt power to operate one electrical device. 14. 1
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B-5 B-5 OPERATION ENGINE OPERATION CAUTION WARNING USE DIESEL FUEL ONLY DO NOT RUN THE ENGINE AT EXCESSIVE Purchase diesel fuel in quantities that will be used SPEEDS. The maximum allowable high idle speed within 30 days, to assure freshness. for the RANGER 8+ DIESEL is 3750 RPM, no load. ------------------------------------------------------------------------ Do NOT adjust the governor screw on the engine. STARTING THE ENGINE Severe personal injury and damage to the machine can result if it is
